Introduction

Printed circuit boards (PCBs) are essential components in most electronic devices and products. They provide the foundation to mount and connect electronic components using conductive copper tracks and pads. While PCBs were traditionally made using time-consuming and expensive processes, Express PCB services now allow custom PCBs to be ordered quickly and affordably.

Express PCB services provide a fast turnaround time, allowing you to get custom designed PCBs delivered to your doorstep in just a few days. This speed is extremely useful for prototyping new products and verifying designs before mass production. Express services are also inexpensive, with some offering PCBs for as little as $5 per board.

In this comprehensive guide, we will cover everything you need to know about ordering express PCBs. We will look at:

• Benefits of using an express PCB service
• How to design your custom PCB
• What to consider when placing your PCB order
• How to upload PCB design files
• Additional services like assembly and testing
• How to review your PCB order and approve it for production
• What to expect for delivery times and final costs
• Troubleshooting and support if issues arise

Follow the steps outlined in this guide and you will be able to quickly and easily get your own custom designed PCBs delivered to your address in just a few days.

Benefits of Using an Express PCB Service

Ordering PCBs through an express service offers significant benefits:

Fast Turnaround Time

Express services aim to manufacture and ship out PCBs as quickly as possible. The fastest turnaround times are 24 hours or 1-3 days. This rapid pace is extremely useful for:

• Prototyping designs quickly
• Testing new iterations of products
• Verifying boards before large scale manufacturing

The ability to get boards produced and delivered in just a day or two allows you to progress your projects much faster.

Low Minimum Order Quantities

Many express services allow you to order as few as 1 or 2 boards at a time. This is a huge advantage compared to using traditional domestic or overseas PCB manufacturers that may require minimum orders of 50-100 boards.

Ordering just a few boards is perfect for prototyping or verifying small projects. You don’t need to worry about paying for a large number of boards upfront.

Lower Costs

Express PCB services aim to offer affordable boards, with some options starting at around $5 per board. Even complex boards with many layers are reasonably priced.

The ability to order just a few boards at a low cost is extremely useful for trying out new ideas without breaking the bank.

High Quality

Reputable express PCB manufacturers use advanced processes and equipment to produce boards with excellent quality. They utilize precise machining, imaging, etching, and plating to manufacture boards reliably and accurately.

You can be confident you will receive professionally made boards with clean finishes, thin layers, and precise details. Quality is often on par with regular PCB services, just delivered faster.

Domestic Supply Chain

Most express services are based domestically in the United States or Europe. This means you are purchasing directly from a local manufacturer with a short and efficient supply chain.

Boards can be manufactured and shipped out quicker without any long distance shipping or customs delays. You’ll also have an easier time communicating and providing feedback.

How to Design Your Custom PCB

Before using an express PCB service, you first need to design your printed circuit board. This involves using PCB design software to lay out the board and route connections.

Here is a brief overview of the PCB design process:

1. Choose Software

There are many PCB design software options available. Some popular choices include:

• Eagle – Widely used, owned by Autodesk. Free version available.
• KiCad – Open source and free PCB design suite.
• Altium – Advanced professional level software with premium pricing.
• Orcad – Made by Cadence, feature rich software.
• DipTrace – Affordable and easy to use option.

Evaluate different options to find software that fits your budget and feature needs. Many have free versions available.

2. Layout the Board

Create the board outline and start placing footprints for components. Arrange parts logically and ensure adequate spacing. Include important markings like polarity indicators.

Group related circuits together, minimizing track lengths for critical connections. Follow best practices for PCB layout and design.

3. Connect Components

Use the routing tools to connect component pads with copper tracks. Follow traces between points, avoiding collisions. Use vias to jump between layers. Design ideal track widths based on current levels.

Double check connections match the circuit schematic and achieve the required functionality.

4. Finalize the Design

Run a design rule check to catch any errors. Simulate the board to verify critical nets. Add useful markings like assembly notes, logos, ratings, and board information.

Generate manufacturing files ready for PCB fabrication and assembly. Save backup copies of your design.

What to Consider When Placing Your Order

Once you have your custom PCB design ready, it’s time order manufacturing. There are several factors to consider:

Choose a Reputable Manufacturer

Select a well-known express PCB company with positive reviews and feedback from customers. This generally indicates reliable quality, fast turnaround, and good service.

Some of the top options include:

• PCBWay – Very fast turnaround starting under 24 hours.
• JLCPCB – Extremely low prices starting at $2 per board.
• OSH Park – Known for purple PCB color and quality.
• Seeed Studio – Popular service with Fusion PCB offering.

Pick Shipping Options

Faster shipping will increase costs but get boards delivered quicker. Slower economy delivery takes longer but saves money.

If speed is critical, upgrade to express 1-3 day shipping such as DHL. This ensures the fastest door-to-door delivery.

Choose Layers and Thickness

Basic boards are 2 layers, while complex designs may use 4, 6 or more layers. Each extra layer adds cost. Pick the layer count required for your circuit complexity.

1.6mm thickness is standard. Go up to 2.4mm for boards requiring more durability and mechanical strength.

Select Special Finishes

Standard boards have a basic HASL (Hot Air Solder Leveling) finish. Upgrades like immersion gold, ENIG, or hard gold improve solderability and shelf life. These add cost but may be worth it for longevity or connectivity.

Determine Quantity

Order the number you need for prototyping and testing. Many manufacturers have order minimums starting at just 1 or 2 boards. Only produce more if certain of the design.

Include Testing

Add functional testing to verify boards work correctly. Testing can catch errors in design or manufacturing. This gives added assurance before using boards in final products.

Check Final Price

The total price is impacted by quantity, shipping, layers, thickness, and any upgrades selected. Ensure the complete order is still within your project budget before confirming.

Uploading Your PCB Design Files

To manufacture your board, the PCB company needs your design files. Here is how to prepare and upload these:

Export Manufacturing Files

Your PCB software can export design files in the Gerber format needed for fabrication. This includes separate layers for copper, silkscreen, solder mask, drill, etc.

Always double check layers are mapped correctly and export settings are configured properly in your software.

Generate Drill Files

Export the Excellon drill file containing hole sizes and locations. NC drill files are also sometimes needed. Provide both if your software supports it.

Include Documentation

Any component libraries, drawings, datasheets, assembly notes, BOM or diagrams are helpful to include. This gives the manufacturer additional context for your design.

Compress Files

Package all the PCB files and documentation into a single ZIP file. This makes uploading easier and avoids missing any critical files.

Upload to Manufacturer

Use the board order form on the PCB company website. Sign up for an account if needed and provide your order details. Then upload your zipped design files for manufacturing.

Submit Order and Payment

Double check all details including shipping address, quantity and options. Submit payment to place the official order. Many services accept credit cards or Paypal.

You will then receive a confirmation with estimated delivery timeframe and updates when manufacturing begins.

Additional PCB Assembly and Testing Services

In additional to just bare PCB fabrication, express manufacturers offer extra services like assembly, testing, stencils, etc:

PCB Assembly

Get boards with components pre-soldered in place. Submit your bill of materials, pick placements, and provide instructions. Skilled technicians will assemble boards for you.

Functional Testing

Have your populated boards electrically and functionally tested to verify the design performs correctly before shipping out. Catch flaws early.

Stencils for Solder Paste

Laser cut stencils allow applying solder paste precisely before component placement. Useful for soldering small SMD parts.

Component Procurement

Let the assembly provider purchase and source all the required components for your bill of materials so you don’t have to.

Quick-Turn Assemblies

Fast assembly and order turnaround time is available, sometimes in as little as 24 hours. Great for rapid prototyping.

Certifications

Some companies can provide certified assemblies that pass testing standards like IPC Class 2 or 3. Useful for high reliability products.

Take advantage of these services to get fully functioning boards delivered. Just upload your assembly BOM, instructions, and gerbers. Handle payment and approve the order.

Reviewing and Approving Your PCB Order

After placing your order, the PCB company will prepare manufacturing files known as gerber proofs. It is important to carefully review these:

Check Layer Previews

Examine images or PDF previews of every PCB layer being fabricated. Verify traces, pads, mask, silkscreen, etc match your original design.

Confirm Drill Locations

Check drill and hole placement images to ensure they precisely match footprints and vias in your design.

Review Solder Mask Expansion

Solder mask expansion settings control spacing around exposed pads. Verify this expansion matches your design rules.

Check Minimum Trace Sizes

Inspect trace width previews. Confirm even thin traces meet original spec and have not been widened.

Look for Missing Copper

Check for any missing copper or mask that may indicate import issues with your design layers.

Submit Approval or Feedback

If the gerber proofs look accurate, provide approval for the manufacturer to continue to PCB fabrication. Or submit markup images or details of any issues found that require correction.

Carefully inspecting proofs avoids errors getting baked into your boards. Take time to thoroughly review before approval.

What to Expect: Delivery Timeframes

After approving manufacturing, your PCB order will get scheduled for production based on current capacity and demand. Here are typical delivery timeframes:

1-3 Day Express

Fastest express service delivers boards in just 24 to 72 hours. Requires paying extra for 1-3 day DHL express shipping. Perfect for urgent prototyping needs.

5-7 Day Standard

With Economy or Standard shipping, expect delivery in 5 to 7 business days on average. This costs less than express shipping. Balance of speed and affordability.

10-15 Day Budget

Slowest budget shipping takes 10 to 15 days typically. Useful for less urgent orders where maximizing value outweighs delivery speed.

Queue Times

Note that 1-3 day ‘turnaround time’ usually just refers to manufacturing time. It does not include order processing, shipping transit or possible wait time in queues. So total delivery still takes longer in most cases.

What to Expect: Final PCB Costs

Pricing depends on many factors but express boards can be very affordable. Here are typical costs to expect:

Bare PCB Costs

• Basic 2 layer boards around $5 per board
• Standard 4 layer boards $15 – $50 each
• Advanced 6+ layer boards $100 – $200 each

Assembly Costs

• Basic assembly starts around $30 – $50 per board
• Complex assemblies $100+ per board

Shipping Costs

• Economy shipping ~ $15 – $30
• Standard shipping ~ $30 – $60
• Express 1-3 day ~ $60 – $150

Minimum Order Quantities

• Many companies allow orders of just 1 or 2 boards
• Typical minimums are 3-5 boards for assembly
• Volume discounts available for larger quantities

Troubleshooting and Support

If any issues come up during your express PCB order, contact the manufacturer for quick resolution:

Submit Replacement Order

If boards have functional or quality issues, request a replacement order. Most companies will expedite a revised order quickly.

Markup Design Reviews

For design related problems found in prototypes, submit markup images to highlight fixes needed in the design files.

Request Manufacturing Investigation

For defects possibly introduced in manufacturing, the company can perform a detailed investigation and find the process root cause.

Get Engineering Support

If needed, ask to discuss your design with an engineering support representative to troubleshoot problems.

Provide Feedback

Give constructive feedback on the ordering process, manufacturing quality, or delivery issues. This helps the company improve.

Frequently Asked Questions

Here are answers to some common questions about ordering from express PCB services:

How quickly can I get PCBs?

The fastest turnaround is typically 24-48 hours including manufacturing and express shipping. More common is 5-7 day delivery.

Can I order just one PCB?

Yes, many manufacturers allow single board orders for prototyping. Minimums are often 1 or 2 boards.

What are PCB panelization options?

PCBs can be panelized to manufacture multiple boards on a large panel for efficiency. Discuss options with your provider.

What file formats do PCB companies need?

Gerber (RS-274X) and Excellon drill files are standard. Some may request additional layers like paste maps.

Can PCBs be ordered assembled?

Yes, full assembly services are available. Submit your BOM, placements, and instructions and boards will ship with components soldered.

How are components sourced for assembly?

You can provide components or use the company’s procurement services to buy parts directly for you based on your BOM.

What quality certifications do companies have?

Ask manufacturers about certifications like ISO-9001. Some offer IPC Class 2 or 3 certified PCB assembly.

Can I approve my order online?

Yes, you can review gerber proofs on the company website and provide approval feedback and markup images online.

How do I pay for express PCB orders?

Most accept common payment methods like credit cards and PayPal. Some accept wire transfers from corporate accounts.

Conclusion

I hope this guide gives you a comprehensive overview of using an express PCB manufacturing service to order fast and affordable custom printed circuit boards. The ability to get boards shipped in just a few days with no minimum order quantity can greatly accelerate prototyping and product development.

With an optimized PCB design, thoughtful component selection, detailed assembly instructions, and careful order review, you can have high quality custom boards delivered to your door surprisingly quickly and inexpensively.

Take the time to thoroughly check PCB proofs before approval, provide any assembly documents needed by technicians, and don’t hesitate to contact the company with questions. This will ensure the best experience having your boards expertly made and smoothly delivered.

The fast turnaround, engineering support, and exceptional value offered by express PCB services makes them an indispensable tool for any electronic product designer, prototyper or hobbyist. Take advantage of these capabilities to give your next project a big boost!