Why Is There Such a Big Difference in PCB Prototyping Prices? Uncovering the Hidden Factors Affecting Costs!

March 12, 2025

The factors influencing PCB prototyping prices are far more complex than you might think! In addition to common visible factors such as board type, number of layers, size, and process, there are many often-overlooked "hidden costs" that impact the final quotation.

This article will take you deep into the various factors affecting PCB prototyping prices and reveal the truth behind the price differences!

1. Board Quality: The "Foundation" of PCBs

Board Types:

FR-4: The most common epoxy glass cloth substrate, cost-effective, and suitable for most applications.

High-Frequency Boards: Made with special resins and copper foil, featuring low dielectric constants and low loss factors, ideal for high-frequency signal transmission. These are significantly more expensive than FR-4.

For example, Rogers RO4350B high-frequency boards offer excellent electrical and mechanical performance, widely used in wireless communication and radar systems.
Another example is Panasonic Megtron6 (M6) R-5775, a high-speed, low-loss material designed for high-speed digital circuits. It features extremely low dielectric loss and stable electrical performance, making it suitable for advanced applications like 5G communication and data centers.

Aluminum Boards: Use aluminum as the base material, offering excellent heat dissipation, suitable for LED lighting and power modules.

Ceramic Boards: Use ceramic as the base material, providing superior thermal conductivity, heat resistance, and insulation, ideal for high-power and high-temperature environments.

Board Brands: Well-known brands like Shengyi, Kingboard, and ITEQ offer stable and reliable quality but at a higher price.

Board Grades:

Grade A:The highest grade, suitable for electronics requiring high reliability, such as military and medical applications.
Grade B: Suitable for general electronics, such as consumer electronics and communication devices.
Grade C: Suitable for electronics with lower reliability requirements, such as toys and lighting.

2. Production Process: The "Precision Carving" of PCBs

Minimum Trace Width/Spacing: The smaller the trace width and spacing, the higher the production requirements, the lower the yield, and the higher the cost. For example, a PCB with 3mil/3mil traces is significantly more expensive than one with 5mil/5mil traces.

Number of Layers: The more layers, the more complex the process, and the higher the cost. For example, a 4-layer board is more expensive than a 2-layer board.

Special Processes:

Blind/Buried Vias: Vias that connect outer and inner layers without penetrating the entire board, increasing wiring density but at a higher cost.
Via-in-Pad: Placing vias on pads to save space, but this increases processing difficulty and cost.
Impedance Control: Controlling the impedance of signal lines to ensure signal integrity requires precise calculations and processing, increasing costs.

3. Surface Finish: The "Outer Layer" of PCBs

HASL (Hot Air Solder Leveling): The most common surface finish, relatively inexpensive, but with average solderability and shelf life.
ENIG (Electroless Nickel Immersion Gold): Offers excellent solderability and a long shelf life but at a higher cost.
OSP (Organic Solderability Preservative): Low cost and environmentally friendly, but with inferior solderability and shelf life compared to ENIG.
Others: Such as immersion silver and electroplated gold, which are more expensive and suitable for special applications.

4. Other Factors:

Delivery Time: Rush orders typically incur additional expedited fees.
Order Quantity: The larger the prototyping quantity, the lower the cost per board.
Manufacturer Qualifications and Scale: Large, well-known manufacturers usually charge higher prices but offer better quality and service.
Shipping Method: International express shipping can significantly increase costs.

How to Choose the Right PCB Prototyping Manufacturer?

Don’t Just Chase Low Prices: Extremely low prices may indicate compromised quality or hidden risks.
Clarify Your Needs: Choose the appropriate board type, process, and service based on product requirements and budget.
Compare Multiple Options: Obtain quotes and samples from multiple manufacturers for a comprehensive comparison.
Evaluate Manufacturer Qualifications and Reputation: Choose experienced and reputable partners.