Exploring the Costs of Custom PCBs and PCBA

Custom printed circuit boards (PCBs) and printed circuit board assembly (PCBA’s) are central to innovation in medical devices, aerospace systems, defense electronics, and industrial electronics. But with performance requirements comes complexity and cost. Understanding what drives cost in a custom PCB/PCBA program enables better decision-making, fewer surprises, and more reliable long-term performance.

This guide outlines the technical and operational cost factors of custom PCBs and PCBA’s. It also describes how EI Microcircuits supports customers through precision manufacturing, integrated services, and lifecycle cost control.

What Drives costs in a custom PCB.

Core Cost Drivers in Custom PCB Design

PCB Manufacturing Cost Factors

PCB Assembly Cost Considerations

Assembly costs for custom PCBs vary with part count, process complexity, and inspection criteria. Key cost elements include:



• Component sourcing, especially for long-lead, high-reliability, or specialized parts
• SMT and through-hole process complexity, including fine-pitch BGAs and high-density layouts
• Conformal coating, selective soldering, or overmolding as part of environmental protection
• Inline inspection such as AOI, X-ray, and ICT to verify placement, solder joint quality, and electrical performance
• Labor for manual assembly, troubleshooting, or rework during early production phases

Testing is often the most overlooked cost area. Functional test development, fixture fabrication, and validation protocols all require planning and documentation. We integrate functional testing and in-circuit test options as part of our turnkey manufacturing system.

Volume, Lead Time, and Cost Trade-Offs

At EI Microcircuits, we support scalable builds with the same engineering rigor and documentation standards. Our systems are designed to support low-to-medium volume, high-mix programs without compromising quality or traceability.

Hidden and Lifecycle Costs

The full cost of a custom PCB program includes more than materials and labor. Program leads must also account for:



• Engineering spin cycles caused by inadequate DFM or test planning
• Supplier management complexity from disaggregated build partners
• Regulatory risk due to incomplete documentation or process validation
• Field failure risk and warranty claims due to undetected manufacturing defects
• Configuration control and revision tracking across the product lifecycle

Lifecycle cost can often exceed the initial build cost. Designs that are difficult to test, source, or rework introduce long-term risk. Our integrated approach mitigates these issues with traceability systems, documentation control, and proactive supply chain management.

EI Microcircuits’ Approach to Cost-Efficient US PCBA

We approach cost control from a systems perspective. Our processes are structured to reduce failure modes, increase first-pass yield, and optimize total cost of ownership. Key elements include:

Key Takeaways