What is Express PCB?
Express PCB is a service offered by many PCB manufacturing companies that allows customers to get their PCB orders processed and shipped quickly, often within a few days. This is in contrast to standard PCB orders which may take weeks to be produced and delivered.
Express PCB services are ideal for prototyping, small batch production, and time-sensitive projects where you need working boards as soon as possible. The tradeoff is that express orders typically cost more per unit than standard orders.
Advantages of Ordering Express PCBs
There are several key benefits to choosing express PCB manufacturing over standard lead times:
1. Fast Turnaround
The biggest advantage of express PCB is the quick turnaround time. Most manufacturers can produce and ship express orders within 1-5 days, getting you the boards you need fast. This is much quicker than standard orders which often have lead times of 2+ weeks.
2. Rapid Prototyping
When you’re developing a new electronic product, it’s important to be able to quickly test and iterate on designs. Ordering express pcb prototypes allows you to get real boards in your hands fast so you can validate your design, make changes, and move development forward without delays.
3. Meet Deadlines
If you have a hard deadline for a project, express PCB services can be a lifesaver. With guaranteed fast processing and shipping, you can be confident your boards will arrive on time. This is especially important if delays would be costly or cause you to miss a critical window of opportunity.
4. Small Batches
Another advantage of express PCB ordering is the ability to get small quantities of boards produced quickly and economically. Since setup and tooling charges are often lower for express orders, it can be more cost-effective to make a small express order rather than a large standard order if you only need a limited number of boards.
How to Prepare Your PCB Design Files
Before you can submit an order for express PCBs, you need to have your board designed and the necessary files ready to send to the manufacturer. Here are the key steps:
1. Design Your PCB Layout
The first step is to create your PCB layout using electronic design automation (EDA) software. Popular options include KiCad, Eagle, Altium Designer, and Fusion 360. Make sure your design follows good PCB layout practices and the manufacturer’s design rules and capabilities.
2. Generate Gerber and Drill Files
Once your layout is complete, you need to generate the Gerber files and drill files that the manufacturer will use to fabricate your board. Gerber is the standard file format for PCB designs. It consists of a separate file for each layer of the board, plus additional files for solder mask, silkscreen, etc. Drill files specify the location and size of all holes that need to be drilled in the board. Your EDA software can automatically generate the required Gerber and drill files from your PCB layout.
3. Create a Readme File
It’s a good idea to include a readme file with your design files that provides additional information and instructions to the manufacturer. This can include things like:
– Your contact information
– Order details (quantity, lead time, shipping method, etc.)
– Any special requirements or notes about the design
– A list of the included design files
4. Compress and Send Files
Finally, compress all your design files (Gerbers, drill files, readme, etc.) into a single ZIP archive. This makes it easy to upload and send to the manufacturer when placing your order.
Choosing an Express PCB Manufacturer
With your design files ready to go, the next step is selecting a manufacturer for your express PCB order. There are many companies that offer express PCB services, so it’s important to choose one that meets your needs and provides good value. Here are some factors to consider:
Lead Times and Shipping Speed
One of the most important considerations is how quickly the manufacturer can process your order and deliver the finished boards. Look for companies that offer fast guaranteed lead times for express orders (ideally 1-5 days or less). Also consider the shipping options – if you need boards delivered overnight or in 2-3 days, make sure the manufacturer has those expedited shipping services available.
Pricing
Of course, price is another key factor. Express PCBs will naturally cost more than standard orders, but prices can vary significantly between manufacturers. Look for a company that offers competitive pricing for the quantities and specifications you require. Be sure to compare the total cost including shipping fees.
Capabilities
Not all manufacturers have the same capabilities when it comes to pcb fabrication. Some may be limited in terms of the minimum feature sizes, layer counts, materials, surface finishes, etc. they can handle. If your design requires any special or advanced manufacturing capabilities, make sure to choose a company that can meet those needs.
Quality and Reliability
When ordering PCBs, you want to be confident you’ll receive high-quality boards that meet your specifications. Look for manufacturers with good reputations for quality and reliability. Check reviews from past customers and see if the company has any quality certifications like ISO 9001.
Customer Service and Support
Finally, consider the level of customer service and support offered by the manufacturer. If you have questions or issues with your order, you want to be able to get help quickly from knowledgeable and responsive support staff. Look for companies with good communication and a commitment to customer satisfaction.
Some of the top express PCB manufacturers to consider include:
| Manufacturer | Lead Times | Capabilities | Pricing |
|---|---|---|---|
| PCBWay | 24-48 hours | Up to 16 layers, HDI, flex, rigid-flex | $5 setup fee + $10-$50 per board |
| OSH Park | 2-5 days | Up to 4 layers, standard specs | $10 per sq in ($5 prototype) |
| Seeed Studio | 3-7 days | Up to 16 layers, standard and advanced | $10 setup fee + $1-$20 per board |
| NextPCB | 1-2 days | Up to 28 layers, HDI, flex, metal core | $0 setup fee, $15-$100 per board |
The Express PCB Ordering Process
Once you’ve chosen a manufacturer, actually placing your express PCB order is usually a simple process. While the exact steps and options will vary between companies, here’s a general overview:
1. Upload Design Files
The first step is providing your PCB design files to the manufacturer. Most companies will have a web interface where you can easily upload your Gerber and drill files. Make sure all the necessary files are included in the ZIP archive you submit.
2. Select Specifications
Next, you’ll specify the technical details of your PCB order, including:
– Number of layers
– Board thickness
– Copper weight
– Minimum hole size
– Surface finish (HASL, lead-free HASL, ENIG, OSP, etc.)
– Solder mask color
– Silkscreen color
– Any special requirements (impedance control, via in pad, etc.)
The options available will depend on the specific manufacturer and their capabilities.
3. Choose Quantity and Lead Time
Then you’ll select the quantity of boards you want to order and the desired lead time. For express orders, lead times may range from 24 hours to 7 days depending on the manufacturer. Keep in mind that smaller quantities and faster lead times will generally mean higher per-unit costs.
4. Select Shipping Method
You’ll also need to choose your shipping method. For express orders, manufacturers will typically offer fast options like overnight or 2-3 day air shipping. The cost will vary based on your location and the speed of shipping you select.
5. Review and Submit Order
Before finalizing your order, carefully review all the details and options you’ve selected. Make sure everything looks correct, as changes may not be possible (or may incur extra fees) once the order is submitted. If you have any questions or concerns, contact the manufacturer’s support team for assistance. Once you’re ready, submit your order and proceed to payment.
6. Payment
Express PCB orders are usually paid for upfront by credit card or PayPal. The total cost will include the base cost for your PCBs based on the options selected, any setup or tooling fees, and shipping charges. Some manufacturers may offer discounts for larger orders or repeat business.
Tracking and Receiving Your Order
After your order is submitted and paid for, the manufacturer will begin processing it right away. For express orders, fabrication and shipping often begins the same day the order is received.
Most manufacturers will send you an order confirmation with a tracking number once your PCBs have shipped. You can use this tracking number on the carrier’s website (DHL, FedEx, UPS, etc.) to check the status of your package and get an estimated delivery date.
When your package arrives, carefully inspect the boards for any damage that may have occurred during shipping. If everything looks good, you’re ready to start building!
Frequently Asked Questions
How much does express PCB service cost?
Express pcb costs vary between manufacturers and depend on factors like the size and complexity of the board, quantity ordered, and lead time selected. In general, expect to pay a premium of 20-50% or more compared to standard PCB pricing for the added speed. Setup fees may also be higher for express orders.
What’s the fastest possible lead time for express PCBs?
Some manufacturers offer lead times as quick as 24-48 hours for simple 1-2 layer designs. For more complex boards (4+ layers, HDI, flex, etc.), the fastest available lead times are typically 3-5 days.
Is there a minimum quantity for express PCB orders?
No, one of the advantages of express ordering is the ability to get small quantities produced quickly and economically. Most manufacturers have no minimum quantity for express orders – you can often order just a single prototype if needed.
What files do I need to submit for PCB manufacturing?
To have your PCBs manufactured, you’ll need to provide Gerber files for each layer of the board, plus drill files specifying the location and size of holes. Your PCB design software can easily generate these files from your board layout. It’s also a good idea to include a readme file with notes for the manufacturer.
Can I get a refund or reorder if there are problems with my express PCBs?
It depends on the specific manufacturer and the cause of the issue. If the problem is due to a manufacturing defect, reputable companies will usually offer to refund or replace the boards at no extra cost to you. However, if the issue is due to a design mistake on your end, you may be responsible for the cost of a reorder. It’s important to carefully review your design before submitting and to choose a manufacturer with good quality control and customer support.
Conclusion
Express PCB services are a great option when you need high-quality boards manufactured and delivered quickly. By following the steps outlined in this guide, you can easily order pcbs that meet your needs and get your project up and running in no time.
Remember to carefully prepare your design files, choose a reputable manufacturer that offers the capabilities and lead times you require, and double-check all your options before submitting your order. With a little planning and attention to detail, you can take your electronics projects from concept to reality faster than ever before.