PCB Assembly Cost Calculator
BOM Cost Analyzer
Enter your Bill of Materials to estimate component costs and find optimization opportunities.
| Reference | Part Number | Description | Package | Qty | Unit Price | Total | Action |
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Design for Assembly (DFA) Tips
Standardize Component Packages
Use common package sizes like 0402, 0603, or 0805 for passives. This reduces unique feeder positions and speeds up assembly. Avoid mixing imperial and metric sizes.
Cost Impact: -15% AssemblyMinimize BGA & Fine-Pitch Components
BGAs require X-ray inspection and increase rework costs. Use QFP or QFN alternatives when possible. If BGAs are necessary, ensure adequate via-in-pad design.
Cost Impact: -$50-200 per designPanel Optimization
Design boards to fit efficiently in standard panel sizes (typically 18"×24" or 21"×24"). Add V-score or mouse-bite break-away tabs for easy depaneling.
Cost Impact: -20% PCB CostSingle-Side Assembly When Possible
Single-sided boards require only one reflow pass, reducing handling, time, and potential defects. Reserve bottom-side for simple passives only if needed.
Cost Impact: -30% AssemblyComponent Orientation Consistency
Align all polarized components (ICs, diodes, capacitors) in the same orientation. This reduces placement errors and speeds up visual inspection.
Cost Impact: -10% QC TimeAvoid Hand Soldering Requirements
Design all connections for machine soldering. Through-hole components should be wave-solderable. Avoid wires, cables, or components requiring manual placement.
Cost Impact: -$0.50-2.00 per boardInclude Test Points
Add accessible test points for critical signals. Use standard 1mm or 0.9mm test pads compatible with flying probe testers. Plan for ICT or functional testing.
Cost Impact: Enables -40% Debug TimeAdd Fiducial Markers
Include at least 3 fiducial marks (1mm copper circles with 2mm clearance) for automated optical alignment. Place them asymmetrically to prevent 180° rotation errors.
Cost Impact: Required for SMTCost Optimization Strategies
Increase Order Quantity
Setup costs are distributed across units. Moving from 100 to 500 units can reduce per-unit assembly cost by 40-60%. Consider ordering annual requirements upfront.
Consolidate Component Sources
Reduce unique part numbers by standardizing values (e.g., use 10kΩ everywhere instead of 9.1k, 10k, 11k). Each unique part adds $2-5 in handling costs.
Turnkey vs Consigned
Turnkey assembly (CM sources components) often costs less than consigned due to bulk purchasing power. Let your CM quote both options.
Design for Panelization
Optimize board dimensions for maximum panel utilization. A 2"×3" board may cost more than 2"×2.5" that fits 20% more per panel.
Use Standard Lead Times
Express and rush services can add 50-200% to assembly costs. Plan ahead and use standard 2-3 week lead times when possible.
Replace with Alternates
Specify 2-3 alternate manufacturers for each component. This gives your CM flexibility to source from available stock at better prices.
Quantity Price Comparison
See how pricing changes across different order quantities to find your optimal order size.