How Much Does It Cost To Get An Industrial Control PCB Assembled?
Industrial control PCB assembly is pivotal in making things run smoothly in modern manufacturing and automation industries.
From the machines that build our cars to the systems that power our factories, these PCBs (printed circuit boards) form the backbone of industrial operations. But if you're here, you probably wonder, "What will this essential component cost me?"
Good question. The cost of assembling an industrial PCB assembly isn’t straightforward—it depends on many factors. Whether you’re looking to assemble low-volume PCB assembly runs for a niche application or need fast PCBA services for a time-sensitive project, the price can fluctuate based on complexity, production volume, component sourcing, and even how quickly you need it done.
In this blog, we will discuss all the factors that influence the cost of industrial control PCB assembly and help you better budget for your next project.
Spoiler alert: while some elements are out of your control (like the availability of specific components), there are plenty of ways to optimize and save money.
So, let’s dive in.
Understanding PCB Assembly Costs for Industrial Control Systems
The rise of automation, AI, and IoT (Internet of Things) means that industrial PCB assembly has never been more critical. PCBs control machinery, monitor systems, and ensure seamless operation in the automotive, robotics, and energy industries.
But what does getting an industrial control PCB assembly project off the ground cost? The answer lies in understanding how different factors—such as the size of the production run, the complexity of the board, and the availability of components—can drive up or reduce expenses.
For instance, a smaller production run—like a low-volume PCB assembly—will generally be more expensive per unit than mass production. This is because setup costs and labor are spread over fewer units.
On the other hand, more complex designs with multiple layers or dense component placement can drive costs higher due to the need for advanced equipment and specialized labor.
Global supply chain issues, such as the semiconductor shortage, can also impact prices. When key components are hard to find, the cost of sourcing them rises, affecting the overall industrial PCB assembly budget.
Factors Affecting Industrial Control PCB Assembly Costs
To give you a clearer view of what we discussed above, let’s explore the key factors that influence the price of PCB assembly.
1. Volume of Production
Volume is one of the most significant factors in controlling PCB assembly costs industrially. The higher the production run, the lower the per-unit cost becomes. This is especially true for low-volume PCB assembly.
When producing in smaller quantities, fixed costs like setup fees and equipment calibration are spread over fewer units, leading to a higher price per board.
Conversely, these overheads are divided among many units in high-volume production, reducing the overall cost.
2. PCB Complexity
The complexity of your PCB design plays a massive role in determining cost. Complex boards with multiple layers, intricate designs, or dense components require more sophisticated equipment and expertise.
For example, if your design includes SMT (surface mount technology) and through-hole components, the assembly process becomes more challenging and expensive.
Moreover, the number of layers on the board increases the complexity. A simple two-layer board will cost significantly less than a ten-layer board packed with microprocessors and specialized components. So, as complexity rises, does the price tag on industrial PCB assembly?
3. Component Sourcing and Availability
If your PCB requires specialty or hard-to-find components, expect the price to increase. The global semiconductor shortage, which many industries still feel the effects of, has caused a rise in component prices. This means that sourcing parts for your industrial control PCB assembly can become costly if the required components are in limited supply.
In addition, if components are being sourced from multiple suppliers across different regions, you might face extra shipping costs, further driving up assembly expenses.
4. PCB Material and Substrate
The type of material used for your PCB can influence costs. For example, boards made from FR-4, a standard laminate, tend to be cheaper than high-performance substrates like Rogers or ceramic-based materials, often used in high-frequency or extreme temperature environments. The cost difference between these materials can be substantial, with specialty materials raising the price per unit.
5. Board Size
Larger PCBs naturally require more material and resources for assembly, which can lead to increased costs. The board’s physical size affects the base material costs and the equipment needed for assembly. Large boards may require more complex handling during manufacturing, leading to higher costs.
6. Surface Finish
The type of surface finish you choose, such as OSP (Organic Solderability Preservative) or HASL (Hot Air Solder Leveling), affects the overall cost. ENIG is a more expensive finish but offers better performance, especially for high-reliability applications like industrial PCB assembly. In contrast, HASL has high-density boards.
7. Solder Mask and Silkscreen
The color and complexity of your solder mask and silkscreen also affect cost. While green is the standard solder mask color, other colors like red, black, or blue may increase the overall expense. Additionally, intricate silkscreen designs, particularly those involving multiple colors or tight tolerances, can drive up costs due to the need for precision.
8. Lead-Free vs. Leaded Solder
Compliance with RoHS (Restriction of Hazardous Substances) regulations requires lead-free solder, which can add to the cost due to its higher melting temperature and the need for specialized equipment. Leaded solder is less expensive but may not be an option, depending on your industry requirements.
The Impact of Turnaround Time on Assembly Costs
Turnaround time is critical in managing assembly costs, directly affecting efficiency, labor, and production. Understanding its impact helps optimize processes and control expenses for better profitability. Let's explore further.
1. Fast PCBA Services
Time is often of the essence in PCB assembly, especially when a project is time-sensitive or has a tight deadline. Opting for fast PCBA services allows you to get your boards assembled and ready for use in days rather than weeks. However, this speed comes at a cost.
Fast-turnaround PCBA services are usually more expensive than standard services because they often require dedicated production lines or overtime labor to meet quick deadlines. If your project demands a tight turnaround, be prepared to pay a premium for the speed.
2. Standard vs. Express Services
Let’s break it down: standard assembly services typically offer lead times of 1-2 weeks, while express services can deliver PCBs in as little as 24-48 hours. The difference in price between these two options can be significant.
While a standard order might be more cost-effective, an express order will raise your budget—but if the project deadline depends on it, that extra expense may be necessary.
Breakdown of Industrial PCB Assembly Costs
Let’s examine the components contributing to the total price of industrial PCB assembly to help you better understand the cost structure.
1. Labor Costs
Labor costs are critical in the total cost of industrial control PCB assembly. These costs vary based on the region where the PCB is manufactured. For example, countries with lower labor costs, such as China or India, typically offer more affordable assembly services than regions like North America or Europe, where labor is more expensive.
Labor-intensive processes, such as through-hole soldering or manual component placement, will increase costs as they require skilled technicians. Additionally, the complexity of the PCB design can further drive up labor costs if it involves intricate layouts or requires specialized expertise.
2. Equipment Usage
The type of equipment used for assembly is another important cost factor. Advanced machinery, such as pick-and-place machines for surface-mount technology (SMT) or selective soldering for through-hole components, can contribute significantly to costs(
Additionally, using specialized equipment for high-precision assemblies, such as X-ray machines for inspecting complex solder joints, adds to the price. Equipment costs can be exceptionally high for low-volume PCB assembly, where the fixed costs of setting up machinery are spread across fewer units.
3. Quality Testing & Certifications
Ensuring that your PCB meets industry standards and is fully functional requires rigorous testing, which can substantially increase the overall cost. Standard testing methods include Automated Optical Inspection (AOI) and In-Circuit Testing (ICT). Still, more complex boards may require X-ray inspection or functional testing to verify the assembly is sound.
For industries like aerospace or medical, certifications such as ISO 9001 or UL can also be a requirement, adding to the expense. While these costs can seem high, they are essential for avoiding costly errors or product failures later on.
4. Prototyping Costs
A prototype can be essential before total production, especially in industrial control PCB assembly. However, prototyping is often more expensive per unit because the setup costs are not spread across many boards.
Prototyping typically involves custom designs and small production runs, which can increase the cost. Additional factors, such as multiple iterations and testing, also drive up prototyping expenses, but this phase is crucial for identifying potential design flaws and optimizing the final product.
5. Shipping & Logistics
PCB shipping costs can vary depending on the shipment's size, weight, and destination. Customs duties and taxes may also increase the costof international shipments.
If you’re working with a manufacturer overseas, expedited shipping for fast PCBA services can significantly increase the price. Safe packaging—especially for delicate, high-value PCBs—might involve extra care and materials, further contributing to logistics costs.
6. Component Placement
The density and type of components placed on the PCB significantly influence costs. Boards with many components or those requiring both SMT and through-hole components generally cost more to assemble. SMT processes tend to be faster and cheaper, especially for high-volume production, while through-hole assembly, which is often manual, can add labor costs.
Additionally, any need for custom component placement will raise the cost, especially in low-volume PCB assembly runs.
Cost-Saving Tips for Industrial Control PCB Assembly
Now that we’ve outlined the factors driving costs let’s look at practical ways to save money without sacrificing quality.
1. Design for Manufacturability (DFM)
One of the most effective ways to reduce costs is by optimizing your design for manufacturability (DFM). This means simplifying your design to make it easier—and cheaper—to produce.
For example, reducing the number of layers, opting for standard components, or minimizing the need for manual intervention can lower assembly costs. A well-optimized design ensures a smoother, more cost-effective production process.
2. Partnering with Reliable Suppliers
Partnering with reliable suppliers can also help cut costs. Not only can they source components at competitive prices, but they may also offer bulk discounts or package deals if you work with them consistently. Suppliers with solid track records can also ensure faster turnaround times and better quality control, which is critical for industrial applications.
3. Balancing Speed and Cost
As discussed, opting for fast PCBA services will drive up costs. However, not every project requires express services. You can save money by opting for a longer lead time, mainly if your project isn’t time-sensitive. Balancing speed with cost is critical to finding the exemplary service for your budget.
Estimating the Right Budget for Your Project
So, how much does it cost to get an industrial control PCB assembly? It depends. Factors like production volume, PCB complexity, component sourcing, and lead time all influence the final price. For low-volume PCB assembly, you can expect to pay more per board compared to high-volume production, and opting for fast PCBA services will drive up costs even further.
As a rough estimate, the cost for a simple, two-layer PCB in a low-volume production run could range from $100 to $500 per unit, while more complex boards with additional layers and components could cost upwards of $1,000 or more per unit.
If you want an exact figure for your project, it’s always best to contact an expert who can provide a detailed quote based on your requirements. Considering the factors discussed, you’ll be better equipped to estimate the proper budget for your next industrial PCB assembly project.
