What is Low Volume PCB Fabrication?

Low volume PCB fabrication refers to the manufacturing of printed circuit boards in small quantities, typically under 100 units. This is in contrast to high volume production which may involve thousands or even millions of identical boards. Low volume fabrication is commonly used for prototyping, testing out new designs, or fulfilling orders for niche products that don’t require large production runs.

The challenge with low volume PCB manufacturing is that it can be expensive on a per-unit basis compared to high volume production. This is because the setup costs and labor involved in creating the PCBs is spread out over a smaller number of units. Many PCB factories have high minimum order quantities and are not well-equipped to handle small batches efficiently.

Advantages of Low Volume PCB Fabrication

Despite the higher per-unit costs, there are several key advantages to low volume PCB fabrication:

1. Faster turnaround times – With smaller batches, the boards can be fabricated and shipped more quickly compared to large production runs that may take weeks or months. This allows for faster iterative development of prototypes.

2. Lower upfront costs – Ordering a small number of boards limits your financial risk and upfront investment compared to committing to a high volume order. This is especially important when testing out a new design that may still have bugs to work out.

3. More flexibility to make changes – Low volume orders make it easier to modify the design between batches based on testing and feedback. With high volume production, you’re locked into a particular design once the fabrication begins.

4. Ability to test the market – Low volume runs let you gauge interest and validate the market before ramping up to full-scale production. This helps avoid getting stuck with a large inventory of boards that may not sell.

PCBWay – A Leader in Low Volume PCB Fabrication

One company that has built a strong reputation for low volume PCB fabrication is PCBWay. Founded in 2003, PCBWay is based in China but serves clients worldwide. They offer a wide range of PCB fabrication services including both prototyping and small batch production.

Key features and benefits of PCBWay’s low volume fabrication service include:

• No minimum order quantity
• Rapid prototyping with turnaround times as fast as 24 hours
• Instant online quoting and ordering
• Wide selection of materials and specifications
• Design for manufacturing (DFM) to identify any design issues
• Excellent customer service and support

By not requiring a minimum order quantity, PCBWay makes it easy and affordable to fabricate boards even if you only need a couple units. Their online quoting system lets you instantly calculate the price based on your required specifications. You can then place the order with just a few clicks and pay by credit card or PayPal.

PCBWay Capabilities

PCBWay’s extensive capabilities allow them to handle a diverse range of PCB designs and requirements. Their specifications include:

Capability	Range
Number of Layers	1 – 16
Material	FR-4, aluminum, flexible, Rogers, etc.
Minimum Hole Size	0.2mm
Copper Thickness	1 oz – 6 oz
Solder Mask	green, red, yellow, blue, white, black
Surface Finish	HASL, lead-free HASL, OSP, immersion gold, etc.
Max Board Thickness	3.5mm

With this broad range of options, PCBWay can fabricate boards for almost any application from simple single-sided boards to complex multilayer designs. They use state-of-the-art equipment and processes to ensure high quality and reliability.

Ordering Process

Placing an order with PCBWay is a simple 3-step process:

1. First, you upload your Gerber files and select the PCB specifications such as dimensions, quantity, layers, thickness, color, etc.

2. Next, you add any additional services like stencils or assembled boards. PCBWay will analyze your design and point out any issues or violations of their capabilities.

3. Finally, you add the items to your cart, select shipping, and submit payment to complete the order. Most orders are fabricated and shipped within just a few days.

Here’s an example of the instant price quote for a 2-layer 50mm x 50mm FR4 board:

Quantity	5	10	50	100
Unit Price	$5.00	$2.80	$1.00	$0.80
Lead Time	2 days	2 days	3 days	4-6 days

As you can see, the price per unit drops significantly as the quantity increases but even at just 5 units it is quite affordable. The fast lead times of only a few days are also very attractive compared to other manufacturers that may take several weeks.

PCBWay vs Other Low Volume Manufacturers

To see how PCBWay compares to other low volume PCB manufacturers, let’s look at a quick side-by-side comparison with two popular alternatives – OSH Park and Seeed Studio Fusion PCB.

	PCBWay	OSH Park	Seeed Fusion
Prototype Qty	≥ 5	3	≥ 5
Price per in^2	$0.50	$1.00	$0.69-0.85
Lead Time	2-6 days	12 days	3-8 days
Instant Quote	Yes	No	No

PCBWay has the advantage in terms of lower prices, faster turnaround times, and the convenience of instant online quotes. OSH Park and Seeed Fusion PCB are still good options but may be better suited for certain niche requirements rather than the flexibility that PCBWay provides.

Tips for Successful Low Volume PCB Orders

While PCBWay strives to make the ordering process as simple as possible, there are a few tips you should keep in mind to ensure your low volume PCB order is trouble-free:

1. Make sure your design matches PCBWay’s capabilities and design rules. Consult their website for the latest information and reach out to their support team if you have any doubts.

2. Carefully check your Gerber and drill files before submitting. Use a Gerber viewer to verify the layers are correct.

3. Consider panelizing your design to fit multiple boards in a larger panel. This can help reduce the cost per board.

4. If possible, choose a standard thickness and color to avoid additional fees and increased lead times for custom options.

5. Be mindful of the additional services like solder stencils, flying probe tests, etc. These can quickly add to the cost for low volume orders.

By following these guidelines you can avoid any unexpected issues or delays with your low volume PCB order. Don’t hesitate to ask PCBWay for guidance if you’re unsure about anything during the ordering process.

Frequently Asked Questions

To wrap up this article, here are answers to some common questions about PCBWay’s low volume fabrication service:

What file formats does PCBWay accept?

PCBWay accepts standard Gerber RS-274X and NC drill files. You can export these from any major PCB design software package.

What shipping options and rates does PCBWay offer?

PCBWay provides DHL, FedEx, and standard airmail shipping to most countries worldwide. The rates vary based on weight and destination but for a small batch of boards it typically starts around $15-20. You will get a shipping quote during checkout.

Does PCBWay offer any discounts?

Yes, from time to time PCBWay has promotional offers and discounts especially for first-time customers. Check their website and social media pages for any current discount codes.

Can I get a PCB fully assembled by PCBWay?

Yes, in addition to PCB fabrication, PCBWay also offers PCB assembly services with sourcing of components. The cost is very competitive for low volume assembly but you will need to supply a bill of materials (BOM) and centroid file.

What if I have a problem with my PCB order?

PCBWay offers a quality guarantee on their boards and will work with you to resolve any issues. They have a responsive support team that you can contact by email, phone, or live chat. In the unlikely event of a defect, they will refabricate the boards at no cost.

By choosing PCBWay for your low volume PCB needs, you can bring your electronics projects to life quickly and affordably without compromising on quality. Their combination of advanced manufacturing capabilities, fast turnarounds, and stellar customer service make them the ideal partner for prototyping and low volume production. So the next time you need a small batch of PCBs fabricated, give PCBWay a try and see the difference for yourself.