6 Common PCB Design Decisions That Increase Manufacturing Costs
… and how DFM helps prevent them
Designing a printed circuit board is always a balance between electrical performance, mechanical requirements, cost, and manufacturability. While a PCB may function exactly as intended, certain design decisions can make it significantly more expensive or time-consuming to manufacture.
Many of these challenges can be identified long before production begins through a Design for Manufacturability (DFM) review. By evaluating the design from a manufacturing perspective, engineers can reduce assembly complexity, improve yields, and avoid unnecessary production costs.
Here are six common PCB design decisions that manufacturing engineers frequently review before a product enters production.
1. Mixing SMT and Through-Hole Components Without a Clear Need
Many electronic assemblies combine Surface Mount Technology (SMT) and through-hole components. However, adding through-hole components without a clear functional reason often increases manufacturing complexity.
An SMT-only assembly typically moves through a highly automated production line. Once a design includes through-hole components, manufacturers may need to introduce wave soldering, selective soldering, or hand soldering, depending on the PCB layout and component mix.
This does not mean designers should avoid through-hole technology. Connectors, transformers, high-current terminals, and mechanically stressed components often benefit from through-hole mounting. Instead, engineers should ensure every through-hole component provides a functional advantage that justifies the additional manufacturing process.
2. Component Placement That Limits Automated Assembly
Component placement affects much more than PCB layout.
Placing components too close together, positioning connectors near board edges, or locating tall components beside smaller devices can reduce automation efficiency. These decisions make assembly and inspection more challenging while increasing the likelihood of manual rework.
During a DFM review, manufacturing engineers evaluate the layout to ensure the PCB moves efficiently through pick-and-place equipment, soldering operations, and automated inspection systems while maintaining high production yields.
3. Designing a Board That Requires Excessive Hand Soldering
Hand soldering remains an essential part of electronics manufacturing for prototypes, specialized assemblies, and certain through-hole components. However, avoidable design decisions can increase the amount of manual soldering required during production, driving up manufacturing costs.
Common examples include:
- Components placed too close together
- Connectors with limited soldering access
- Non-standard packages that require manual assembly
- Mixed technologies that prevent automated soldering
Reducing unnecessary manual operations improves consistency, shortens production time, and helps lower manufacturing costs.
4. Limited Access for Testing and Inspection
A PCB may perform well during development but still create production challenges if the design limits access for testing and inspection.
Manufacturing teams need access for activities such as:
- Functional testing
- Flying probe testing
- In-Circuit Testing (ICT)
- Programming and debugging
Likewise, AOI and X-ray inspection systems require clear visibility of components and solder joints to verify assembly quality. Designing with testing and inspection in mind helps identify issues earlier while reducing troubleshooting time during production.
5. Poor Panelization Strategy
Manufacturers rarely assemble PCBs individually. Instead, they build multiple boards together on production panels to maximize efficiency.
If designers overlook panelization during development, manufacturers may need to redesign the panel layout or rely on less efficient handling methods.
An effective panel design considers:
- Panel size
- Tooling strips
- Fiducial placement
- Breakaway tabs
- Depanelization methods
Well-designed panels improve throughput, reduce handling time, and minimize manufacturing waste.
6. Waiting Until Production to Consider Manufacturability
One of the most expensive design decisions is postponing manufacturability reviews until production begins.
Engineering changes become significantly more expensive once teams build prototypes, order components, or start production. Even relatively small revisions can affect lead times, tooling, procurement, and production schedules.
Reviewing manufacturability early allows engineering and manufacturing teams to identify potential issues before they become costly production problems.
How DSM Helps Reduce Manufacturing Risk
At DSM, Design for Manufacturability is integrated into the New Product Introduction (NPI) process rather than treated as a final checkpoint.
Our engineering team reviews every assembly from a manufacturing perspective, evaluating component selection, PCB layout, soldering methods, inspection requirements, panelization, and production flow before volume manufacturing begins.
Because DSM offers SMT, wave soldering, selective soldering, hand soldering, automated inspection, testing, and box build under one roof, we can recommend manufacturing processes that balance cost, quality, and long-term reliability.
The result is a smoother transition from prototype to production, fewer engineering changes, and more efficient PCB assembly.
Looking For Feedback On Your Next PCB Design?
Contact DSM to learn how our DFM reviews help OEMs improve manufacturability, reduce production risk, and accelerate time to market.
Reach out to DSM today: dsmsales@dynamicsourcemfg.com
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