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Master the Layout: Essential Strategies to Lower Your PCB Costs
At ASC Sunstone, we know that time is money, but so is technology. Whether you are a long-time customer or just starting your first project with us, optimizing your design for manufacturing (DFM) is the most effective way to keep your project on budget without sacrificing quality.
We’ve compiled the best money-saving strategies from our engineering team to help you get the most value out of every order.
1. Optimize Your Board Geometry. Bigger isn’t always better for your wallet.
Minimize Size: Board size is a major cost driver, especially as it impacts panel utilization. Keep your layout compact to reduce material costs.Stick to Standard Shapes: Custom shapes and complex cutouts increase fabrication time. Use standard square or rectangular boards whenever your end product allows.
2. Simplify Your Stack-up. Complexity adds cost.
Limit Layers: Evaluate if you can achieve your goals with fewer layers (e.g., using a 2-layer board instead of a 4-layer).
3. Use Generous Tolerances. Pushing the limits of technology often pushes your price up.
Trace & Space: Keeping your trace and space geometry above 6 mil (100 microns) allows for faster, more affordable fabrication.Via Sizes: While tiny vias are impressive, a 13-mil via is more cost effective than smaller alternatives.Standard Drills: Use standard drill sizes (like 0.3mm or 0.5mm) to avoid the need for specialized tooling.
4. Choose Value-Driven Materials & Finishes
The "Old-School" Value: Green solder mask is the industry standard for a reason, it offers the best value.Standard Finishes: Opt for HASL (Hot Air Solder Leveling) for standard applications. It’s reliable and the most budget-friendly finish available.Stick with FR-4: Unless your project absolutely requires high frequency or specialty materials, FR-4 is your most cost-effective friend.
5. Plan Ahead & Scale Up
Lead Times: This is often the biggest expense. If your schedule allows, choosing a longer lead time can significantly drop your per-board price.Order in Bulk: Take advantage of economies of scale. Ordering for future needs now reduces the "setup" cost per board and protects you from future price fluctuations.
Try Our Free Tools: Use PCB123® to get real-time pricing and DFM feedback as you design, so you can see exactly how your choices affect your quote.
Pro-Tip: Don’t let mechanical requirements force you into unnecessarily tight thickness tolerances. Being generous with your parameters leads to a more robust board at a lower cost.
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DFM Essentials
The guidelines offered in this book are based on both ASC Sunstone's recommendations and IPC standards
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DFM Essentials Companion Guide
This guidebook also outlines common CAM issues and emphasizes early collaboration with fabricators to avoid costly design errors
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