- What is a prototype PCB?
- Types of PCB prototypes
- Why is PCB prototyping important?
- Fabricating PCB prototypes
- Summary
A PCB (printed circuit board) prototype is a model or sample of how the final PCB will look and function. A printed circuit board prototype or low-cost PCB prototype is a small device used to connect electronic components to ensure the smooth operation of a product. The process determines whether the proposed PCB design will perform as expected, thus revealing any possible defects and thus allowing the designer to make any necessary changes. Any other improvements or alternatives the designer may have in mind are also introduced at this stage. No new product can be mass-produced without PCB prototyping services cannot simply start without a prototyping phase.
What is a prototype PCB?
Prototyping is essential, especially in electrical manufacturing. Therefore, in the case of a circuit, you need a prototype PCB, simply a product sample that allows you to check whether the circuit design works properly.
Pcb prototyping does not necessarily reveal any defects because sometimes the design is perfect. Once the prototype PCB is completed, the electronic components of the product are connected to a PCBA (printed circuit board assembly), usually with the help of soldering. The manufacturer or customer can then provide comments on the PCB and any other suggestions/improvements they may have. The PCB prototyping service designer should always be prepared for any possible outcome, so any rework at this stage should not be considered an additional cost. Bypassing PCB prototyping and engaging in mass production of PCB prototype boards will only set it up for failure and will certainly be disastrous in terms of wasted effort, time and money.
In most cases, PCB prototypes are usually used for basic testing. However, for PCB prototyping, PCB prototypes need to be fully functional, a test which components work in the primary stage, and possibly check if the entire circuit design is correct.
Types of PCB prototypes
There are different PCB prototypes available for testing various circuit designs. In addition, you will most likely have to use multiple PCBs when building a circuit. therefore, some of these PCB prototypes include
1. working prototype PCB
This PCB prototype contains all the functions and features of the final design and is fully functional. You can use this PCB prototype to test for errors in your design and check the finished design.
2. Visual Model
The main purpose of the visual PCB model is to test the PCB design’s physical characteristics and the board components’ structure. You can use a graphical model as a prototype because it is an economical and easy way to test and review PCB designs.
3. Functional PCB Prototype
This PCB prototype is closest to your final design. Usually, with few economic differences, it shows exactly how your plan will work and look.
4. Proof-of-concept prototype PCB
The main goal of this type of PCB prototype is to test whether your design is usable. Therefore, it does not have all the features of your circuit design. It only needs the main functionality.
Why is PCB prototyping important?
The nature of PCB prototyping can best be understood by clearly defining the board development process. Circuit boards are typically cyclical and contain many iterations. Each iteration includes design, build, and test phases designed to improve the quality of the design. The technique of continually modifying the board until all errors are corrected, and the desired quality is obtained is called PCB prototyping.
Engineers who design printed circuit boards (PCBs) typically generate prototype boards before fully manufacturing the boards for the final product. Multiple prototype runs are often included in developing the final manufactured PCB and for a good reason.
PCB prototypes can be developed for boards with limited functionality to test proofs of concept for individual features before producing a more complex finished product.
As features are added to PCB prototyping, increasingly complex builds can ensure quality and desired results. This is especially useful in more complex PCB prototyping, where failures after final manufacturing can lead to costly rework and redesigns.
The importance of PCB prototypes in the fabrication process
PCB circuit boards are an important part of almost all electronic devices we use daily. As such an important component, most original equipment manufacturers require sophisticated PCB design and manufacturing due to their inability to withstand any failures when used in applications. However, we can never avoid some unseen problems and small errors that threaten the board’s function. This is where the prototype PCB becomes especially important; it is an early sample of the board whose sole purpose is to check the complete functionality of the design. Although it may seem like an extra step, the prototype PCB performs a pre-production analysis of the board before you begin a full production run. The following is an analysis of why PCB prototypes are so important in processing.
1. Accelerate overall production.
Highly accurate PCB prototypes help minimize iterations and rework during the production phase. PCB prototyping allows defects to be identified early on, providing vendors with enough time to correct them before production. In addition, with prototypes, it is easier for vendors to communicate with customers and let them know about key design elements. Customers can also request changes or modifications, which can be time-consuming in the later stages of production.
2. Testing.
The PCB prototyping process is not only a random error detection process. On the other hand, it is a critical step that includes several test processes such as temperature variation test, power variation test, shock resistance test, Etc. All these tests check the board’s ability to work under harsh environmental conditions. Designers also carefully check all components and functions to ensure they work as expected. This minute checking allows for faster and more accurate PCB creation during production runs.
3. Minimize costs.
Early detection of errors helps vendors to easily and instantly correct errors at a minimal cost. This is not the case when faults are found in the production phase. Finding PCB design defects at a later stage requires huge amounts of money to fix them. This will, in turn, completely affect the project budget and schedule. In addition, PCB prototyping allows vendors to arrange materials and components in advance according to design specifications. They can also find and test cost-effective components, materials, and assembly methods. Overall, PCB prototyping minimizes the rush of last-minute material purchases while enabling them to make appropriate decisions about manufacturing methods.
Prototype PCBs help board manufacturers and customers clearly understand lead times, pricing, and potential component inventory issues. This leads to improved and more efficient PCB processing. Prototype PCBs allow board factories to experiment with different designs and components and select the most suitable at a budget-friendly price. The process helps give partners a clear understanding of what to expect from a production run. It allows projects to be completed efficiently, minimizing material loss, expense, and effort. There is no doubt that board prototyping is a good way to measure the final product’s functionality.
Areas where prototyping can benefit PCB manufacturing, including
Creation of circuit pattern molds.
If the factory machinery cannot properly create pattern dies (for example, due to the inability to meet very tight tolerances), it will not be able to manufacture the electrical circuit boards properly.
Component functionality.
Prototyping the PCB makes it possible to ensure that all connections work properly and that components function properly without interference or conformance issues.
Circuit board configuration and layout.
PCB prototyping allows you actually to see how the board will function. You may decide you need a dual panel rather than a single one, and vice versa. Seeing the physical schematic of a printed circuit board may illustrate different, more optimal ways of laying out circuits and components. Considering the potential cost of production errors, investing in PCB prototypes is never a bad idea.
Make sure to work with a PCB design engineer and PCB prototyping supplier who has the expertise and ability to guide you through the PCB prototyping process and can assist with design and production. The importance of knowledge and experience in such a detail-oriented process cannot be underestimated.
Fabricating PCB prototypes
The build phase of development is the stage where the physical manifestation of the design is constructed. In each iteration of the PCB prototyping cycle, a new board is built or manufactured and then tested. During PCB prototyping, testing is done primarily to verify functionality and operation. The Pcb manufacturing process will result in a bare PCB board with no components attached. Although, the location of the electronic components placement or overlay area and the corresponding pads are laid out. Subsequently, the components are attached to the board using through-hole soldering, surface mount technology (SMT), or a combination of both to produce the final PCB assembly (PCBA) ready for testing. Depending on the complexity and manufacturing of the printed circuit board, this process can take days or even weeks to produce a prototype.
Summary
This article has covered PCB prototyping basics and manufacturing process matters. PCB prototyping is almost as important as the actual production process. Regardless of the relative complexity of the PCB, the process is always very complex. Testing through prototypes can and should be done before production to ensure that the PCB functions as expected.