PCB manufacturing involves using various base materials, with copper-clad boards—often FR4 with copper layers on both sides—being the most common. FR4 is considered the most cost-effective and reliable material for multilayer PCBs. However, some small manufacturers use low-quality FR4 to reduce costs, especially for prototypes. While using cheaper materials may seem viable, it can compromise quality control. Larger PCB manufacturers, such as Shenzhen SysPCB, use high-quality FR4 materials from suppliers like Kingboard, Shengyi, and Isola to ensure consistent quality, particularly in mass production. High-volume production can reduce costs without compromising material quality, often making high-quality FR4 just as affordable as low-quality alternatives.
With the advancement of innovative technologies, PCB manufacturers have enhanced printed circuit board assembly by adopting surface-mount technology (SMT). SMT is now the predominant method for electronic circuit board production due to its smaller size, improved performance, and compatibility with automated assembly using pick-and-place machines, minimizing the need for manual intervention. Unlike traditional wired components, which required manual placement due to their complex fitting requirements, SMT allows for almost entirely automated assembly. PCB assembly services provide a cost-effective way to update electronic devices rather than purchasing new ones. SMT production is mainly carried out in cleanroom environments that are ESD-safe to protect sensitive components from static damage. Shenzhen, China, is a major hub for electronics manufacturing, offering a wide range of components and assembly services at competitive prices, helping to reduce costs for PCB and PCBA sourcing.
Surface-mount technology (SMT) is a method for constructing electronic circuits where components are directly mounted onto a PCB's surface using solder pads made of tin-lead, silver, or gold-plated copper. The connection between the PCB and components relies on the quality of these solder joints. The longevity of PCBA boards depends on proper maintenance. A Shenzhen-based PCB manufacturer recommends a semi-annual maintenance routine that includes cleaning dust with special fluid, drying the board, and checking components for overheating or leakage. Annual maintenance should include dust cleaning, testing electrolytic capacitor capacity, replacing old or damaged capacitors, and reapplying thermal grease to high-power devices to ensure effective heat dissipation and prolong the board's lifespan.
Printed circuit boards (PCBs) form the foundation of modern electronic circuits and can be made from various materials. The most widely used material is FR4, a glass fiber-based board, while the original PCBs were made from paper phenolic aldehyde. Single-sided boards, which have components on one side and wiring on the other, emerged in the U.S. in the 1950s with the advent of the transistor. In the mid-1950s, Japan advanced single-sided board production using imported copper foil and phenolic substrates. However, due to limitations in insulation and heat resistance, materials like paper epoxy and glass fiber epoxy resins were later introduced. Today, FR4 substrates are the primary material used for single-sided boards in consumer electronics.
PCB manufacturing involves advanced technologies that improve component sizes, track reduction, and board reliability. Several factors influence the cost of PCBs, such as material quality, number of layers, surface finish, delivery time, board size, process technology, and production standards. Material costs vary based on quality and tolerance requirements, while adding more layers increases production complexity and cost. Surface finishes like immersion gold (ENIG) are more expensive due to longer production times and higher material costs. Delivery time also affects pricing, with faster turnaround times incurring higher costs. Specific manufacturing requirements, such as compliance with IPC Class 3 standards or special board outlines, can further increase the price.
PCB holes, or vias, are essential for connecting different layers within a printed circuit board (PCB) and mounting leaded components. They can be categorized into three main types: blind vias, buried vias, and thru-hole vias. Blind vias connect an outer layer to an inner layer but do not go through the entire board. They help save space and enhance heat transfer but are more expensive than thru-hole vias due to their complex manufacturing process. Buried vias connect two or more internal layers without reaching the outer layers, adding to the difficulty and cost of production.