In PCB projects, cost problems rarely come from a single dramatic mistake. They come from many small design decisions that seem harmless in CAD, but become expensive in production.
At Comtec Labs, we frequently see designs that are electrically sound, pass prototype testing, and still end up costing far more than expected once they reach series production.
This article explains the most common PCB design mistakes that quietly increase production cost, and why manufacturing-friendly design is the most effective cost-control strategy available.
Why PCB Cost Is Often Misunderstood
Many teams focus on the board price per unit.
In reality, total cost is driven by:
Yield loss
Rework and scrap
Assembly inefficiency
Slow ramp-up
Design decisions directly influence all of these factors.
Mistake 1: Overly Tight Tolerances
Tight tolerances increase inspection effort, reduce yield, and slow down production.
If a tolerance does not directly improve functionality, it usually increases cost without adding value.
Mistake 2: Unusual Materials and Stackups
Exotic materials may solve a narrow problem but introduce supply chain risk and higher fabrication cost.
Standard materials scale better and cost less.
Mistake 3: Ignoring Panelization and Assembly
Designs that ignore panelization often suffer from lower assembly yield and higher handling cost.
Panelization is not a manufacturing detail—it is a cost driver.
Mistake 4: Poor Testability
Boards without proper test access require longer test time, manual probing, or reduced coverage.
All of these increase cost.
DFM as the Ultimate Cost-Control Tool
Manufacturing-friendly design does not mean lower performance. It means designing margin, reducing variation, and enabling stable production.
The cheapest board is the one that builds correctly the first time.
Ready to Reduce PCB Surprises?
If you’re navigating complex requirements, tight schedules, or production risk, Comtec Labs offers a full suite of services to streamline your workflow:
PCB design service
PCB prototyping service
PCB component sourcing
PCB component assembly
PCB testing service
PCB repair and modifications
Printed circuit board production
PCB mass production