How Much Does PCB Assembly Cost?

The costs for PCB assembly (PCBA) are composed of several factors. There are no flat rates – every project is different. The main cost drivers are:

• Quantity: Prototypes are more expensive per unit than series production
• Component count and complexity: More components = more assembly time
• Technology: SMD assembly is cheaper than manual THT mounting
• Test requirements: AOI, ICT or functional testing increase costs

Each new project incurs one-time setup costs – so-called NRE costs (Non-Recurring Engineering):

• SMD programming: The pick & place machine must be programmed for each layout
• Stencil: A stainless steel stencil is manufactured for solder paste application
• AOI programming: The optical inspection system must be trained
• DFM review: Manufacturing data is checked for producibility

These costs are incurred only once per project and amortize quickly in series production.

Unit costs depend heavily on the technology used:

SMD assembly (automatic):

• High-speed placement with pick & place machines
• Typically 10,000–50,000 components per hour
• Ideal for small packages (0402, 0603)
• Costs: dependent on placement points and component types

THT assembly (manual or selective):

• Connectors, relays, transformers are inserted through the PCB
• Significantly slower than SMD
• Higher cost per component due to manual labor

Tip: Most modern designs combine SMD for standard components with THT only for mechanically stressed components.

The components themselves often make up the largest share of total costs:

• Standard components (resistors, capacitors): a few cents per piece
• ICs and microcontrollers: CHF 0.50 to CHF 50+ depending on the type
• Connectors: CHF 0.20 to CHF 20+
• Specialty parts: Sensors, modules – highly project-dependent

A good EMS partner like SMTEC AG procures materials at industry prices and advises on alternative components when originals are unavailable.

European manufacturing is more expensive than Asia – but offers clear advantages:

Conclusion: For prototypes and small to medium series, European manufacturing is often more economical when considering total costs (including shipping, customs, and quality issues).

For a specific quote, an EMS partner needs the following documents:

1. Gerber data (RS-274X or ODB++)
2. Bill of materials (BOM) with manufacturer part numbers
3. Pick & place file (Centroid)
4. Assembly drawing
5. Desired quantity and delivery date

The more complete your documentation, the faster and more accurate the quote. SMTEC AG is happy to provide you with a non-binding quote – contact us at smtec.ch/kontakt.