Low-volume PCB assembly is the operation of assembling a minuscule number of printed circuit boards. Unlike mass production, where the total number of boards assembled may be in thousands to hundreds of thousands, low-volume PCB assembly typically involves assembling anything between a few boards to a few hundred. In this article, we, at Rush PCB Inc., discuss why US-based low-volume PCB assembly offers several advantages.
Common Scenarios Where Low-Volume Assembly Is Needed
Low-volume PCB assembly production mode is suitable for situations that involve prototypes, custom builds, pilot or small batch runs, and experimental products.
Advantages of US-based PCB Assembly
Fast PCB assembly in the USA has several key advantages. Primary among them is the quick response to market requirements and rapid adaptations to the personal needs of customers.
What Qualifies as Low-Volume Assembly?
Typical Unit Range
Low-volume assembly typically refers to production quantities limited to a few boards, to a maximum of a few hundred.
High-Mix Low-Volume Projects
With the advancement of technology, many new markets are now emerging. There is an increasing demand for high-mix but low-volume electronic products—a large variety but low quantities of each type of product. Low-volume PCB assembly is eminently suitable for such markets and helps OEMs develop new businesses.
Importance of Rapid Prototyping and Iterative Development
Low-volume PCB assembly serves very well when organizations are involved with simultaneously exploring multiple new products. They require many prototypes assembled in a short time, so they can capture the market before their competitors do.
Another scenario where low-volume PCB assembly helps is when an organization is planning multiple variations of a single product. They too require many prototypes at short periods for their iterative development.
Key Benefits of US-Based Low-Volume PCB Manufacturing
Faster Turnaround Times
Small-batch PCB manufacturing in the USA helps to shorten the time from design to market. This is mainly due to better and faster communication between the client and the manufacturer. The client can immediately convey any necessary changes to the manufacturer, who can start implementing the same as quickly as possible.
Easier Communication
The client and the manufacturer can communicate more effectively when both are in the US. This is mainly because of both being in the same time zone. They can communicate as soon as the necessity arises, and one does not have to wait for the other to wake up or return to the office.
Another factor is that both the client and the manufacturer speak a common language, so there are no ambiguities with translations.
Moreover, since both are in the US, there is a greater possibility of the client and the manufacturer following the same business culture, so the understanding between them is far better than with an overseas person or organization.
IP Protection and Compliance
With US PCB manufacturers, the client has much better opportunities of protecting their IP or intellectual property. With overseas manufacturers, there is always a possibility of differences in laws, which lowers the amount of protection and compliance that the client can expect for their IP.
Flexibility in Material Sourcing and Design Changes
With rapid prototype PCB assembly, there is always the urgency of conveying any design changes to the manufacturer and the latter implementing the same quickly. When both the client and the manufacturer are in the US, this is possible.
For instance, most PCB material sources are in the US. Therefore, a design change involving a change in the material being used has a much greater chance of being implemented easily and quickly when both the client and the small-batch PCB manufacturing are in the USA.
Quality & Reliability
IPC-Certified Facilities
For overseas small-batch PCB manufacturing, it is difficult to assess their claims of being IPC-certified facilities, unless the client visits them in person. This is much easier for small-batch PCB manufacturing in the USA, since most of the IPC-certification bodies also have their offices or branches in the US, and verification is quicker.
Advanced Inspection and Testing Standards
Many overseas small-batch PCB manufacturers claim to have advanced inspection methods and international testing standards in place in their production processes. However, this may be far from the truth, considering that a visit to the assembly facility may turn out to be economically unworthy for the client. This is not so for small-batch PCB manufacturing in the USA, and they ensure quality and reliability through advanced inspection methods like Automated Optical Inspections or AOI, X-ray inspections, and functional testing methods complying with international standards.
Traceability and Documentation Compliance
US-based low-volume PCB assembly partners, if they are ISO certified, must conform to their established quality management guidelines of traceability and documentation. Therefore, the client has complete information about the processes their project has undergone, complete with documented backup.
Support for Design Iteration
Local Support for Engineering Changes
During prototyping, there is a high possibility of the client requiring design iterations for their experimental product. With onshore PCB assembly, the assembler can immediately take up the engineering changes and provide local support for the same.
Real-Time Feedback from Manufacturing Experts
When the manufacturer is a fast PCB assembly in the USA, they are aware of the local market situations, and they can provide real-time feedback to their client. This often helps the client save time and money. For instance, US PCB manufacturers may have advanced information about the impending obsolescence of an electronic component the client is presently using in their project. This allows the client to quickly switch over to an alternative and proceed with their project. An overseas assembler, on the other hand, may have late access to the same information. By this time, the client’s PCBs would have already been delayed because of the unavailability of the component.
Rapid Prototyping and Production in the Same Facility
Most US PCB manufacturers with assembly facilities prefer to have rapid prototyping and production facilities under the same roof. This helps to speed up the entire production process substantially. Change implementation can be a matter of hours rather than days. Overseas manufacturers prefer to offload the prototyping work to another organization. However, this adds another delay in the communication channel, leading to an overall project delay when implementing changes.
Hidden Cost of Offshore Assembly
Shipping Delays, Customs, and Miscommunication
There are several hidden costs of offshore assembly that are not obviously visible. One of them is shipping delays. The greater the geographical distance, more are the chances of delays due to inclement weather, political uncertainties, and business rivalries.
Customs can also cause unwanted delays. Changes in rules, changes in personnel, and variations in laws between countries can lead to unforeseen delays and an increase in costs.
Differences in language, culture, and time zones can lead to miscommunication and ambiguity. This creates delays, defeating the very purpose of fast turnaround, low-volume PCB assembly.
Costly Rework or Failed Batches
Miscommunication and communication delays can lead to costly rework, as there are delays in mistake rectification. Such delays can be very expensive because of late communication for failed batches. By the time information about mistakes reaches the assembler, they have progressed further in their assembly process.
Risk of Counterfeit Components
With overseas assemblers, there is always a large possibility of some counterfeit components finding their way into your assembled boards. This can be due to the non-availability of that component with the assembler, and they being under pressure to complete the project in time.
Conclusion
There is certainly merit in considering a US-based manufacturing partner for your low-volume projects. Being in the same time zone, in similar business cultures, and speaking the same or similar language, communication is simpler, direct, and more effective. This cuts down on miscommunication, ambiguities, and time delays.
With US PCB manufacturers, you have more chances of keeping your IP secure. Choose from an ISO-certified service provider if you want traceability and documentation. You can take advantage of local support and get real-time feedback to cut down on your time-to-market.
You do not need to worry about hidden costs with onshore PCB assembly. Shipping delays are minimal, and hassles from customs are practically non-existent. There are lower chances of the presence of counterfeit components in your assembled board.
If you are looking for low-volume PCB assembly or prototype PCB assembly, you can consider Rush PCB Inc. as your US-based manufacturing partner. With over 20 years of experience in PCB manufacturing and assembly, we can handle your next prototype or small batch with confidence.
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