Although the prototype sits closer to the end of a manufacturable design than the outset, the unique challenges of navigating manufacturing revisions can frustrate budgets and timelines. Prototype designs are not yet set in stone (or rather, fiberglass and epoxy) – the shifting nature of the design means the BOM, schematic, or layout can fluctuate. Even one of these changes can mean a new board revision and prototype production. The best PCB prototype service for designers is one that can deftly adapt to the shifting requirements of the layout and assist design teams with production foresight.
The Effect of Prototyping on Production
The best PCB prototype services must balance the revision’s immediate needs with the project’s long-term goals. Rarely (if ever) are board designs completely static from start to finish: engineers have to consider the cost and availability of components, reduce or increase feature scope, and possibly contend with more drastic redesigns due to changes in enclosure design, shape, application, and more. First, an experienced contract manufacturer (CM) will evaluate the design for potential manufacturability issues. These issues could be related to the precision of the fabrication/assembly equipment or the aforementioned issues with component stock. Identifying and rectifying design issues early in the process will help reduce the total number of prototype revisions, ideally lowering the cost of the production phase and accelerating development toward consumer-ready devices.
As the design evolves, the needs of respective prototype runs can shift dramatically. A manufacturer can offer insight and strike the optimal balance between various manufacturing inputs:
- Cost – Prototyping is less expensive per lot than mass production due to the smaller quantities, but individual board costs can be much higher (definitively so). The time sensitivity of prototypes differs from that of a final design: whereas the latter may have a specific market deadline to hit, the former requires extensive testing, research, and feedback to progress the design. Engineers, layout designers, and manufacturers may eschew traditionally cost-effective purchase strategies to accelerate this development. CMs with extensive vendor relationships can more easily leverage costs with bulk orders and maintain an on-site supply.
- Assembly – Some high-volume productions forgo through-hole components due to their relative inefficiency in packaging and soldering. Because prototypes are less susceptible to the escalating effect of per-board costs, designers may choose less efficient packages for better availability/lead times.
- Testing – Any manufactured board – prototype or otherwise – must undergo extensive testing to validate production and check for defects that could reduce the device’s service life. However, prototype testing has to contend with the design as a moving target. For example, designers may use do-not-install (DNI) components for circuit tuning and balancing parasitics. These components are necessary while establishing the board characteristics, but designers eventually replace them (or eliminate them) after finalizing in-circuit measurements. An experienced CM knows how to balance the testing requirements for electronic fixtures (i.e., net test points on the board’s outer layers) without encroaching on performance.
The Best PCB Prototype Service Depends on Design Needs
Much like the design, approaches to PCB assembly aren’t one-size-fits-all. While prototyping isn’t as the market forces of the final, mass-produced board, these factors can similarly impact production schedules. Broadly, the turnaround time is the most critical factor for the prototype – while turnaround times are a consideration for mass production quantities, cost-effectiveness is usually the primary motivation. Manufacturers can strike a balance between turnaround time and cost, depending on the urgency of getting a prototype board.
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Your Contract Manufacturer for High-Quality Prototype Boards
The best PCB prototype services come from the best CMs; designers will want to ensure their project has the expertise and resources to carry it to the finish line. Given the iterative nature of prototyping, good communication with the CM is paramount. At VSE, our engineers are committed to building electronics for our customers. For over forty years, we’ve been realizing cutting-edge designs with the help of our manufacturing partners.
