What is PCB Panelization?

PCB panelization is the process of arranging multiple identical or different PCB designs on a single large panel for manufacturing purposes. By grouping PCBs together, manufacturers can optimize production efficiency, reduce material waste, and lower overall fabrication costs. Panelization allows for the simultaneous production of multiple PCBs, streamlining the assembly process and minimizing handling time.

Benefits of PCB Panelization

1. Increased Production Efficiency
2. Panelization enables the fabrication of multiple PCBs in a single production run, significantly reducing the time required to manufacture a large number of boards.

3. Automated assembly processes can be utilized more effectively, as machines can place components on multiple PCBs simultaneously.

4. Cost Reduction

5. By producing PCBs in panels, manufacturers can optimize material usage and minimize waste, leading to cost savings.

6. The increased efficiency of panelized production translates to lower labor costs and faster turnaround times.

7. Improved Handling and Shipping

8. Panelized PCBs are easier to handle during the manufacturing process, as they can be treated as a single unit.
9. Shipping and packaging of panelized PCBs are more convenient and cost-effective compared to individual boards.

Screaming Circuits’ Approach to PCB Panelization

At Screaming Circuits, we have developed a robust PCB panelization process that combines advanced technology, skilled professionals, and stringent quality control measures. Our approach ensures that our customers receive high-quality, reliable PCB Panels that meet their specific requirements.

Panelization Design Considerations

When designing a PCB panel, several factors must be taken into account to ensure optimal results. Our experienced engineers consider the following aspects:

1. PCB Dimensions and Spacing
2. The dimensions of the individual PCBs and the spacing between them on the panel are carefully calculated to maximize material utilization and minimize waste.

3. Adequate spacing is maintained to ensure proper singulation (separation) of the individual PCBs after production.

4. Tooling and Fiducial Marks

5. Tooling holes and fiducial marks are incorporated into the panel design to facilitate accurate alignment and positioning during the manufacturing process.

6. These marks serve as reference points for automated assembly equipment, ensuring precise component placement.

7. Breakaway Tabs and Mouse Bites

8. Breakaway tabs, also known as mouse bites, are small perforations or slots placed between individual PCBs on the panel.

9. These tabs allow for easy separation of the PCBs after production while maintaining the structural integrity of the panel during handling.

10. Panel Material Selection

11. The choice of panel material depends on the specific requirements of the PCBs, such as the desired thickness, durability, and electrical properties.
12. Common materials used for PCB panels include FR-4, aluminum, and flexible substrates like polyimide.

Advanced Panelization Techniques

Screaming Circuits employs advanced panelization techniques to accommodate complex PCB designs and ensure optimal manufacturing results. Some of these techniques include:

1. Sub-panelization
2. Sub-panelization involves creating smaller panels within a larger panel, allowing for the production of PCBs with different designs or specifications on the same panel.

3. This technique enables efficient use of panel space and reduces overall production time.

4. Stepped Panelization

5. Stepped panelization is used when PCBs have varying thicknesses or require different layer stackups.

6. By creating stepped regions on the panel, PCBs with different thicknesses can be accommodated without compromising the structural integrity of the panel.

7. Flexible Panelization

8. Flexible panelization techniques are employed for PCBs that require flexibility, such as those used in wearable devices or compact electronics.
9. Special considerations, such as the use of flexible substrates and the placement of bend lines, are taken into account during the panelization design process.

Quality Control and Testing

To ensure the highest quality of our PCB panels, Screaming Circuits implements rigorous quality control and testing procedures throughout the manufacturing process. These measures include:

1. Design Rule Checking (DRC)
2. Before production, the panelization design undergoes thorough DRC to identify any potential issues, such as spacing violations or incorrect hole sizes.

3. DRC helps prevent manufacturing defects and ensures that the panel design adheres to industry standards and customer specifications.

4. Automated Optical Inspection (AOI)

5. AOI systems are used to inspect the PCB panels for any visual defects, such as missing components, solder bridging, or incorrect component placement.

6. This automated inspection process ensures that any issues are identified and rectified before the panels move to the next stage of production.

7. Electrical Testing

8. Electrical testing is performed on the PCB panels to verify the functionality and performance of the circuits.

9. Various testing methods, such as Flying Probe Testing or In-circuit testing, are employed to ensure that the PCBs meet the required electrical specifications.

10. Mechanical Testing

11. Mechanical testing is conducted to assess the structural integrity and durability of the PCB panels.
12. Tests such as bend testing, vibration testing, and thermal cycling are performed to ensure that the panels can withstand the intended operating conditions.

Frequently Asked Questions (FAQ)

1. What is the minimum number of PCBs required for panelization?

2. At Screaming Circuits, we typically recommend a minimum of 5-10 PCBs per panel to justify the panelization process. However, the exact number may vary based on the specific requirements of the project and the size of the individual PCBs.

3. Can different PCB designs be panelized together?

4. Yes, different PCB designs can be panelized together using sub-panelization techniques. This allows for the efficient production of multiple PCB designs on a single panel, reducing overall manufacturing time and costs.

5. How does panelization affect the cost of PCB production?

6. PCB panelization generally leads to cost savings in the long run. By optimizing material usage, reducing waste, and increasing production efficiency, the overall cost per PCB decreases. However, the initial setup costs for panelization may be slightly higher compared to producing individual PCBs.

7. What are the limitations of PCB panelization?

8. PCB panelization has certain limitations, such as the maximum panel size that can be accommodated by the manufacturing equipment. Additionally, complex PCB designs with irregular shapes or intricate features may pose challenges during the panelization process and require specialized techniques.

9. How long does the panelization process take?

10. The panelization process itself is relatively quick, typically taking a few hours to a few days, depending on the complexity of the panel design. However, the overall lead time for PCB production may vary based on factors such as the PCB design, material availability, and production scheduling.

Conclusion

PCB panelization is a vital process in the manufacturing of printed circuit boards, offering numerous benefits such as increased production efficiency, cost reduction, and improved handling. At Screaming Circuits, we have honed our PCB panelization expertise to deliver high-quality, reliable panels that meet the diverse needs of our customers. By considering key design factors, employing advanced techniques, and implementing stringent quality control measures, we ensure that our panelization services exceed expectations.

If you have any further questions or would like to discuss your PCB panelization requirements, please don’t hesitate to contact our team of experts. At Screaming Circuits, we are committed to providing exceptional service and delivering PCB panels that meet the highest industry standards.

Panel Size	Number of PCBs	Cost per Panel	Cost per PCB
12″ x 18″	50	$500	$10
18″ x 24″	100	$800	$8
24″ x 36″	200	$1,200	$6

Table 1: Example of PCB panelization costs based on panel size and number of PCBs.

By leveraging PCB panelization, manufacturers can significantly reduce the cost per PCB, as demonstrated in the table above. As the panel size and the number of PCBs per panel increase, the cost per individual PCB decreases, making panelization an economically viable option for large-scale production.

At Screaming Circuits, we work closely with our customers to determine the optimal panel size and PCB quantity based on their specific project requirements and budget constraints. Our experienced team will guide you through the panelization process, ensuring that you achieve the best possible results while maximizing cost-effectiveness.