PCB production process: which stage has the highest cost

1、 Raw material cost: the basic "burning money" link

Raw materials are the cornerstone of making PCB circuit boards. Among them, copper-clad laminates play a crucial role. Copper clad laminates are composed of copper foil, resin, and reinforcing materials, and their quality directly affects the performance of the circuit board. According to industry data, the cost of copper-clad laminates typically accounts for 30% -40% of the total cost of PCB circuit boards. Like some high-end high-frequency copper-clad laminates, due to their extremely high requirements for material properties, their prices are outrageously expensive. For example, ordinary FR-4 copper-clad laminates may cost only a few tens of yuan per square meter, while high-frequency copper-clad laminates can cost hundreds or even thousands of yuan per square meter.

2、 Manufacturing process cost: high cost of precision work

The manufacturing process is the core link that determines the quality and performance of PCB circuit boards. Among them, the production process of multi-layer boards is particularly complex. Multilayer boards require multiple single-layer boards to be stacked together through processes such as lamination. The more layers there are, the greater the difficulty of the process and the higher the cost. Generally speaking, the manufacturing cost of four layered boards is 50% -100% higher than that of double layered boards. Moreover, in the manufacturing process, processes such as drilling, electroplating, etching, etc. require high-precision equipment and professional technicians. Taking drilling as an example, precise holes need to be drilled on tiny circuit boards, which requires extremely high precision and stability of the equipment. A high-precision drilling machine can cost hundreds of thousands or even millions of yuan, which undoubtedly increases manufacturing costs. In addition, the chemicals used in the electroplating process are also a significant expense.

3、 Testing and Testing Costs: The 'Hidden Killer' of Quality Assurance

In order to ensure the quality and performance of PCB circuit boards, the inspection and testing process is essential. Various defects such as short circuits and open circuits may occur during the production process of circuit boards. Through rigorous testing and inspection, these issues can be identified and fixed in a timely manner. Common detection methods include flying needle testing, automatic optical inspection (AOI), etc. Flying needle testing equipment is expensive and the testing speed is relatively slow. The testing cost per circuit board may range from a few yuan to several tens of yuan. Although automatic optical inspection is fast, the procurement and maintenance costs of the equipment are also not low. According to statistics, the cost of testing and inspection accounts for approximately 10% -20% of the total cost. This is like giving a comprehensive medical examination to a car, although the cost is not low, it can ensure the safe driving of the car.