One of the most common questions asked at the end of a PCB design is:
“Can we build it?”
While this question sounds reasonable, it is often the wrong one. In practice, many PCBs that can be built once cannot be built reliably, repeatably, or at scale.
At Comtec Labs, we regularly see designs that pass prototype builds, only to struggle badly when volumes increase. The issue is rarely whether the PCB is manufacturable in theory, but whether it is manufacturable in practice.
Manufacturable vs Manufacturable at Scale
A PCB can be manufacturable and still be a poor manufacturing choice.
True manufacturing readiness answers deeper questions:
Can it be built with stable yield?
Can it be built repeatedly without constant tuning?
Can it be built at higher volumes without quality loss?
Designs that push process limits may survive NPI, but fail later through yield loss, rework, and inconsistency.
Why Prototypes Give a False Sense of Security
Prototypes are forgiving. Extra inspection, manual fixes, and engineering oversight
mask underlying weaknesses.
In volume production:
Variation becomes visible
Margins disappear
Small issues multiply
This is why “it worked in the prototype” is one of the most dangerous assumptions in manufacturing.
Designing Margin Instead of Capability
Good DFM is not about using the full capability of a process. It is about designing margin.
Margin absorbs variation.
Margin protects yield.
Margin enables scaling.
Designs that rely on best-case conditions inevitably struggle in production.
Repeatability Is More Important Than Complexity
Advanced designs are sometimes necessary. But complexity must be justified.
If a design requires constant process tuning, special handling, or heroics on the production floor, it is not production-ready.
The Right First Question
Instead of asking:
“Can we build it?”
The right questions are:
Can we build it reliably?
Can we build it repeatedly?
Can we build it at scale?
These questions define manufacturing success.
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