In many PCB projects, cost discussions start and end with one number: the board unit price. If that number looks low, the design is considered cost-effective. In reality, this approach hides the costs that matter most.
At Comtec Labs, we regularly see projects where the “cheap” PCB becomes the most expensive option once production begins. The reason is simple: real cost is created in production, not in CAD.
Why Unit Price Is a Poor Cost Metric
Board price per unit ignores:
Yield loss
Rework and scrap
Test time
Slow production ramp-up
Engineering firefighting
These costs often exceed the savings from a lower unit price.
Hidden Cost 1: Yield Loss
Designs that push tolerances, materials, or processes often suffer from unstable yield.
Even a few percentage points of yield loss quickly outweigh small unit-price savings.
Hidden Cost 2: Rework and Repair
Poor manufacturability leads to:
Extra inspection
Manual rework
Field returns
Rework consumes time, labor, and margin.
Hidden Cost 3: Slow Ramp-Up
Designs that ignore manufacturing reality require tuning and iteration during ramp-up.
Time lost here delays revenue.
DFM and Total Cost of Ownership
True cost control focuses on total cost of ownership. DFM reduces variation, stabilizes yield, and shortens time-to-market.
The cheapest board is the one that builds right 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