How Much Does PCB Assembly Cost? A Breakdown for Small and Large Orders
- Harshit Shah
- May 14
- 6 min read
Updated: Aug 8
Printed Circuit Board (PCB) assembly is a vital step in transforming electronic designs into functional products, but one question that always arises is: how much does PCB assembly cost? Whether you're developing a prototype or preparing for mass production, understanding the various factors that influence costs in the PCB assembly process can help you plan your budget more effectively.
In this guide, we’ll break down the cost of assembly for both small and large orders, so you know exactly what to expect and how to keep your project cost-efficient without sacrificing quality.
Table of Contents
Key Factors Influencing PCB Assembly Cost
Several variables play a role in determining PCB assembly price, including:
Board Complexity: The number of layers, component density, and layout intricacies can raise prices.
Component Type and Availability: Surface-mount vs. through-hole components and the need for special parts affect sourcing and handling expenses.
Turnaround Time: Express manufacturing will increase your PCB assembly rates.
Testing Requirements: Advanced testing, such as AOI (Automated Optical Inspection) or X-ray inspection, increases the cost of PCB assembly.
Labour and Location: Geographic region impacts labour charges. Offshore assembly may be cheaper, but lead time and communication challenges must be considered.
What is the Cost Breakdown of PCB Assembly?
Here’s how the printed circuit assembly price typically breaks down:
Setup Costs
These are the initial, one-time charges that manufacturers apply to prepare for your assembly run.
Includes programming pick-and-place machines, stencil creation, and preparing solder paste layers.
Setup costs are largely fixed, so they impact small orders more than large ones.
For projects with multiple board versions or design changes, these costs may increase slightly during the PCB assembly process.
Component Costs
This is often the largest portion of your total assembly cost.
The prices of components like ICs, resistors, capacitors, and connectors depend on market availability.
Special parts, obsolete components, or tight supply conditions can raise the cost significantly.
Using common, in-stock components helps reduce both cost and lead time.
Whether components are supplied by the client (consigned) or sourced by the assembler (turnkey) also impacts the pricing for quick-turn PCB assembly services.
Labour Costs
Labour expenses depend on the complexity of your board and the type of assembly used.
Simple boards using automated machines (SMT) cost less to assemble.
Boards requiring manual soldering, especially with through-hole components or complex layouts, take more time and increase labor charges.
Some regions have higher hourly labour rates, which can also affect your total cost in printed circuit assembly projects.
Testing and Inspection
Testing is critical to ensure your boards function correctly, but it adds to the cost.
Visual inspections and AOI (Automated Optical Inspection) are standard and cost-effective.
More advanced checks, like in-circuit testing (ICT), flying probe testing, or X-ray inspection, increase accuracy but add to the budget.
The level of testing depends on the criticality of your product and customer specifications in the PCB assembly process.
Packaging and Shipping
Often underestimated, these costs can impact your final unit price, especially for international projects.
Custom packaging, ESD-safe materials, and moisture barriers may be required depending on your board's sensitivity.
For overseas orders, international shipping fees, duties, and import taxes can significantly affect your total cost.
Consolidating shipments or choosing slower delivery methods may help reduce shipping expenses when managing Printed Circuit Board (PCB) assembly services.
Cost per PCB Board Orders: Small vs. Large Orders
Order volume dramatically affects PCB assembly costs:
Small Orders (Prototypes, <50 units)
Higher assembly estimate per board due to setup fees spread over fewer units.
Better for testing and iterations.
It may cost $30–$100 per board or more, depending on specs.
Large Orders (500+ units)
Setup costs are amortised, lowering per-board prices.
Bulk purchasing reduces component cost.
Typical low-cost PCB assembly runs may be as low as $5–$20 per board.
Cost Factor | Small Orders (<50 Units) | Large Orders (500+ Units) |
Setup Costs | Higher – fewer boards to spread the cost | Lower – cost spread across many units |
Component Costs | No bulk pricing – costs more per part | Bulk pricing reduces part cost |
Labour Costs | Often manual – more expensive | Mostly automated – lower cost |
Testing & Inspection | Basic testing – extras add cost | More testing at lower cost |
Packaging & Shipping | Higher per unit cost | Lower per unit cost |
Estimated Cost/Board | $30 – $100+ | $5 – $20 |
How to Estimate PCB Assembly Cost for Your Project?
To calculate a realistic assembly estimate, gather the following:
Gerber files and BOM (Bill of Materials)
Order quantity
Required lead time
Testing preferences
Component sourcing (consigned or turnkey)
Using this information, you can request accurate quotes from manufacturers. Always compare vendors, ensuring they offer transparent pricing for their PCB assembly rates.
Interesting Reads: PCB Assembly vs. PCB Fabrication: What to Choose for Your Next Electronics Project
Tips to Reduce PCB Assembly Costs
Simplify the Design: Minimise component count and avoid unnecessarily complex PCB designs.
Use Common Components: Avoid hard-to-source or obsolete parts. Use common printed circuit board components.
Consolidate Orders: Larger batches or Orders lead to PCB assembly low-cost benefits.
Flexible Lead Time: Avoid rush PCB assembly orders unless necessary.
Partner with the Right Manufacturer: A reliable partner like A2ZEMS offers competitive, low-cost PCB assembly without compromising on quality.
If you want to know what benefits you get while choosing electronic manufacturing company so you can also read our new blog on benefits of choosing right electronics manufacturing company
Trends Shaping the Future in PCB Assembly Costs
Looking ahead, several trends are reshaping how manufacturers approach PCB assembly services:
Automation & AI: Enhancing speed and reducing human error while assembkly circuit boards.
Global Supply Chain Optimisation: More localised production to combat component shortages.
Eco-Friendly Materials: Affecting both material cost and compliance-related expenses on assembling the circuit board.
Custom Manufacturing Software: This software helps to streamlining quotes and reduce setup times.
Interesting Reads: Understanding the PCB Manufacturing Process: A Complete Guide
Conclusion
Understanding PCB assembly costs is essential for anyone bringing an electronic product to market. From design complexity to order volume and testing requirements, each factor shapes the total cost of assembly.
By analysing your project needs and working with an experienced, transparent manufacturing partner, you can balance quality, speed, and price—whether you're assembling 10 boards or 10,000.
As a Leading PCB assembly company, we specialise in delivering dependable, cost-effective PCB assembly services that match your project timeline and technical goals. Ready to move forward? Contact us today for a custom quote and see how we can help you bring your ideas to life efficiently and affordably.
Frequently Asked Questions (FAQS)
1. How much does PCB assembly service cost?
The PCB assembly price can range from $10 to $100+ per board, depending on complexity, components, and volume. For large orders, PCB assembly rates typically drop due to bulk efficiencies. Labour, testing, and turnaround time also affect final pricing.
2. How much does it cost to make a small PCB?
A small PCB prototype may cost $30–$70 per board, depending on design complexity, component sourcing, and assembly type. Since setup costs are spread over fewer units, the cost of assembly is higher per board for low-volume runs.
3. How do you calculate PCB assembly cost?
To calculate an assembly estimate, manufacturers consider:
Number of boards
Bill of Materials (BOM) and component costs
Assembly type (manual, SMT, through-hole)
Setup and stencil charges
Testing requirements
Shipping and packaging fees
Accurate files and clear specifications will help you get a reliable quote for PCB assembly costs.
4. How much does it cost to assemble a PCB?
On average, PCB assembly costs range from $10 to $50 per board for mid-volume production. High-complexity boards or fast-turnaround jobs may cost more. Low-volume or prototype orders tend to have higher per-unit prices due to fixed setup costs.
5. What factors influence PCB assembly pricing?
Key factors include:
Board complexity (layers, size, component density)
Component sourcing and availability
Labour and manufacturing location
Testing and quality control needs
Turnaround time
Each of these elements impacts your final printed circuit assembly price.
6. Are there hidden costs in PCB assembly that most businesses overlook?
Yes. Businesses often overlook:
NRE/setup fees (Non-recurring engineering costs)
Stencil creation charges
Shipping and customs for international orders
Testing/debugging services
Parts sourcing premiums during shortages. Identifying these early helps keep your PCB assembly low cost and avoids surprises in your final invoice.
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