PCB Fabrication is the process of turning a circuit design into a physical printed circuit board. It involves layering copper, insulating materials, and solder masks to create the foundation that electronic components will later be assembled onto. High-quality fabrication ensures durability, reliability, and consistency across every board you produce.
What is PCB Fabrication?
Printed Circuit Board (PCB) fabrication is the manufacturing of the actual board itself—before any components are mounted. This includes the creation of copper traces, pads, vias, solder mask, silkscreen, and mechanical outlines. Fabrication defines the electrical pathways and structural backbone for your entire device.
Essential Factors to Consider
- Board Material (FR-4, Rogers, Polyimide, etc.) – Impacts cost, thermal stability, and performance in high-frequency applications.
- Layer Count – Simple boards may use 1–2 layers, while advanced designs require 4–16+ layers. More layers = higher cost and complexity.
- Trace/Space Tolerances – Defines how fine your routing can be; critical for high-speed or dense designs.
- Surface Finish – Options like HASL, ENIG, or immersion silver affect solderability and shelf life.
- Drilling & Vias – Via-in-pad, blind/buried vias, and microvias enable advanced routing but raise costs.
- Quality Control – Look for electrical testing, impedance control, and IPC-6012 compliance.
How to Choose the Right PCB Fabricator
- Capabilities: Ensure the vendor supports your required layer count, finish, tolerances, and via technology.
- Turnaround Time: Prototyping fabs may offer 24–72 hour lead times, while mass production usually takes 1–3 weeks.
- Location: Local fabs provide speed and easy communication, while overseas fabs (China, Taiwan, etc.) often offer lower costs at scale.
- Certifications: For industries like aerospace, automotive, or medical, look for UL, ISO, and ITAR compliance.
- Engineering Support: A good fab will review Gerber and drill files to catch errors before production.
Typical Price Points
Prices vary widely by complexity, size, and quantity. As a rough guide:
- Simple 2-layer prototype boards (5–10 pcs): $5–$50 total (low-cost online fabs).
- 4-layer boards (5–10 pcs): $40–$150 total.
- High-volume, 2-layer boards (1,000+ pcs): < $1 per board.
- High-volume, 6+ layer boards (1,000+ pcs): $5–$15 per board.
Tip: Always optimize your design for manufacturability (DFM). Simple panelization and standard stackups can cut costs dramatically.
Finding the Best Fit
The right PCB fabricator depends on your stage:
- For prototypes: use quick-turn services (like JLCPCB, PCBWay, or OSH Park) to test designs affordably.
- For scaling: partner with a fab that offers volume discounts, quality certifications, and strong supply chain integration.
- For specialized needs: seek out niche providers (e.g., RF boards, flexible PCBs, HDI boards).