It can be like a maze with blindfold finding the correct PCB manufacturer to use your prototypes and small production runs. You desire to have boards of good quality and they should be delivered on time, yet, you do not want to empty your wallet at the same time. Being an independent hardware developer, a startup founders or an engineer in a company that is just starting to grow, it is important to select the right partner to make your project successful.
The good news? Having a little bit of knowledge and the correct attitude, you will be able to locate a manufacturer that will not sell you too slowly or too cheaply and provide the best quality.
Figuring Out What You Really Need
You need to have a clear understanding of what you need, before you begin to contact manufacturers. Do you want to put together a demonstration that merely functions, or do you need to develop prototypes that will be presented to investors or consumers? The solution has a major influence on your needs.
At the prototyping stage, you may be satisfied with standard specifications and extended lead times. However, when you are heading in the direction of a small batch production you will need to consider consistency, testing, and the ability of your manufacturer to expand with you in the future. Your time will be saved by millions of hours of back-and-forth communication by writing down your technical needs, quantity needs, schedule, and budget constraints and going shopping around.
The Hidden Costs That Catch Everyone
This is what the majority of us are taught the expensive way, the price quoted on the board of directors is only the tip of the iceberg. You can easily get 30-50 percent of the final bill on set-up fees, tooling, expedited shipping, testing, and payment processing fees.
Intelligent consumers demand a cost breakdown on a per-unit basis. What do you mean by that per-board price? Will there be a set up fee of new designs? And electrical testing or flying probe testing? Other manufacturers promote low prices but make their profits on these add-ons. Some of them have transparent and all-inclusive prices which may appear expensive at first but cost you less in the long term.
Geography Matters More Than You Think
The place of your PCB supplier does not only influence shipping time. It affects the ease of communication, the quality standards, protection of intellectual property and cost. The common assumption that engineers make is that overseas production is always cheaper, which does not apply to small batches.
In Europe, prototypes have to be done quickly, it may even be cheaper to consider a France PCB manufacturer or a Portugal PCB manufacturer when you consider the speed of delivery of the prototype, the time taken to clear the customs and the importance of being able to visit the factory in case of problems. European manufacturers usually are good at low volume, high mix production, and that is what prototype and small batch work demand.
In the projects where cost sensitivity is a primary concern and where you have more time to spare, the manufacturers in such regions as Turkey or Southeast Asia are interesting in terms of value. A Turkey PCB manufacturer can avail a pleasant compromise between European distance and Asian costs, whereas a Thailand PCB manufacturer could offer exceptional value to slightly larger small batches with tolerable lead times.
The point is it is better to align your geographic option with your genuine priorities and not to make any assumptions.
Quality Indicators You Can Verify
Every manufacturer can say that he/she produces high-quality boards, and how do you check that statement before committing any action? Begin by enquiring about their certifications. The ISO 9001 is a table stake though seek industry specific standards such as the IPC-A-600 of acceptability standards or UL certification in case your products will require them in future.
Ask to see sample boards or ask to see examples of similar work they have done. A manufacturer with confidence will be pleased to share his or her portfolio. Consider their minimum capabilities as compared to their normal capabilities. Do they support the number of layers, trace widths and via sizes your design needs?
There is nothing wrong with requesting references, particularly from customers with whom they are doing similar work. Only a brief chat with a fellow engineer that has dealt with them can tell more than months of research on the web.
Communication Is Your Canary in the Coal Mine
The manner in which a manufacturer responds to the quoting process makes a prediction of the manner in which the manufacturer will respond when issues occur. And issues will always be a thing in the development of hardware.
Are they quick in answering your questions? When you submit a Gerber file do they send you back smart questions regarding your design, or do they just rubber-stamp it? The most successful manufacturers become partners, which recognize probable problems before they turn out to be costly mistakes.
Time zone disparity is important in communication. When you are developing at a rapid pace on a prototype and you have a twelve hour difference between your manufacturer, that delay will add days to your development cycle. The ability to communicate in real time comes in extremely handy when you are trying to troubleshoot.
The Flexibility Factor
The prototype work is unpredictable in nature. You may find yourself being in a hurry to complete one order, and you put the other on hold as you redesign. The way your manufacturer manages this variability will be an indicator of whether they are really configured to do prototype and small batch.
Enquire whether they are flexible on order quantities. Minimum order quantity may be very high by some manufacturers and it does not make sense with prototypes. There are those that do quick-turn, low-volume work. How long is their standard lead time, and what are some of the options to expedite when you are faced with a deadline crisis?
Making Your Final Decision
After you have reduced the number of choices, you can then make a simple comparison table with your highest priorities giving them more weight. Add not only price, but also lead time, quality of communication and technical capabilities.
It is important to keep in mind that the most inexpensive alternative may hardly be the best one. A manufacturer that can provide trusted boards in a timely manner, identify problems during the design phase prior to making the fabrication, and proactively communicate is a premium worth paying a small amount. Whatever money is saved by using the lowest bidder is soon overshadowed by the cost of delayed projects or a failed board.
Begin with a small test order to ensure quality and communication and commit to large volumes. Develop that relationship on purpose, and you will have a dependable partner as your projects develop out of prototypes into production.
