What is PCB Panelization?

PCB panelization involves taking individual PCB designs and arranging them into a larger multi-PCB panel. This panel is what actually gets manufactured, allowing many copies of a PCB to be produced at once rather than individually.

The process of panelization includes:

1. Importing the individual PCB designs
2. Arranging the designs into an optimized panel layout
3. Adding tooling holes, breakaway tabs, and other panel features
4. Generating manufacturing files for the final panel design

Proper panelization is important to ensure high manufacturing yields and minimize wasted material. The panel needs to be designed to withstand the rigors of the assembly process.

Benefits of Using Panelization Software

Panelization can be done manually, but specialized software makes the process much easier and provides several key benefits:

• Quickly import and arrange multiple PCB designs
• Automatically optimize panel layouts to maximize PCB per panel
• Easily add tooling holes, Mouse Bites, breakaway tabs and other panel features
• Catch design issues early before manufacturing
• Generate manufacturing files in industry standard formats
• Streamline communication between design and manufacturing teams

Using panelization software helps ensure the final panel is optimized and ready for a smooth manufacturing process, reducing costs and time to market.

Types of Panelization Software

There are a few different types of software used for PCB panelization:

Software Type	Description
Standalone Panelization Tools	Dedicated software packages that specialize in panelization. Examples include CAM350, DFM Now, and PanelBuilder
PCB Design Software with Panelization	Many PCB design tools like Altium Designer, Eagle, and KiCad have built-in or add-on panelization capabilities
Pre-Production CAM Tools	Panelization is sometimes handled in CAM (Computer-Aided Manufacturing) software by the manufacturer after receiving design files

The choice of panelization software depends on a company’s existing design tools, complexity of panelization needed, and personal preference.

Features to Look for in Panelization Software

When evaluating PCB panelization software, some key features to look for include:

1. Ease of importing PCB designs in standard formats
2. Automatic and manual panel layout tools
3. Design rule checks to catch issues
4. Support for mixed PCB sizes, shapes and thickness in a single panel
5. Ability to add fiducials, tooling holes, and other panel elements
6. Good documentation and customer support
7. Compatibility with your other design tools and manufacturing partners

More advanced panelization needs may require specialized features like those for flexible circuits, RF designs, or Metal-Core PCBs. Ensure the software you choose supports your technical requirements.

Panelization Best Practices

Following some best practices helps ensure reliable, high-quality panel designs:

• Consult with your manufacturer early on their panelization capabilities and guidelines
• Use a robust method like V-groove or perforated break-away tabs to depanelize individual PCBs without damage
• Carefully choose the type, size and location of tooling holes, fiducials and other panel elements
• Allow space between boards for component overhangs, soldermask pullback, and manufacturing tolerances
• Follow good panel design rules for minimum spacing, trace width, aspect ratios, etc.
• Validate panelized designs with your manufacturer before beginning production

Panelization Challenges and Solutions

Even with the help of panelization software, designers can run into challenges like:

Challenge	Solution
Individual PCBs with irregular shapes that are hard to panel efficiently	Get creative with tab patterns and panel layouts to maximize PCB per panel
Fragile PCB substrates that are prone to damage when depanelizing	Use methods like V-groove slots instead of rough break-away tabs
Mixed PCB Thicknesses that require special considerations in assembly	Work closely with your manufacturer to accommodate steps in the panel
Keeping track of different revisions of a design across a panel	Implement a clear PCB version numbering scheme and include it on the panel

Open communication with your manufacturing partner and careful planning during the design process can alleviate most panelization issues.

Popular PCB Panelization Software

Some of the most popular choices for PCB panelization software include:

1. Altium Designer – PCB design software with panelization capabilities
2. CAM350 – Dedicated PCB CAM and panelization tool from DownStream Technologies
3. EAGLE – PCB design software from Autodesk with panelization features
4. GerberLogix – Standalone Gerber editing and panelization program
5. PCB Panelizer – Low-cost, easy to use panelization tool for small businesses and hobbyists

The right choice depends on your budget, technical needs, and compatibility with existing tools and workflows.

How to Get Started with PCB Panelization Software

To get started using PCB panelization software, follow these basic steps:

1. Evaluate your panelization needs and choose appropriate software
2. Install and set up the software, including any libraries and configuration files
3. Gather the individual PCB design files you wish to panelize
4. Create a new panel project and import the PCB designs
5. Arrange the PCBs into an optimized panel layout
6. Add any needed tooling holes, fiducials, or other panel elements
7. Run design rule checks and correct any errors
8. Export manufacturing files like Gerbers, NC drill files, etc.
9. Send the panelized design to your manufacturer for prototyping and production

FAQs

What is the difference between a PCB array and a PCB panel?

A PCB array typically refers to identical PCBs laid out in a grid, while a panel is a more general term that can include arrays and also mixed PCB designs laid out to maximize a manufacturing panel.

Do I need to panelize my PCBs?

Panelization is not required for all PCBs but is very common, especially for smaller boards and higher production volumes. Consult with your manufacturer on whether your design should be panelized.

Can I panelize flex PCBs?

Yes, flex PCBs can be panelized but require special considerations compared to rigid PCBs. Panelization software with specific features for flex circuits is recommended.

Why are there mouse bites on my PCB panel?

Mouse bites are a type of perforated break-away tab used to hold the individual PCBs into the panel securely during assembly but allow them to be easily separated after.

What if I don’t have room on my PCB for break-away tabs?

In cases where the PCB design can’t accommodate tabs, an alternative method like V-groove slots or adding waste material can be used. Work with your manufacturer to choose the best depanelization method.

Conclusion

PCB panelization is a crucial step in electronics manufacturing that benefits from specialized software. Panelization tools make it easier to create optimized panels ready for production, while following best practices ensures high yields and minimal issues during assembly.

With a wide range of panelization software options available, from standalone tools to integrated features in PCB design programs, there is a solution to fit every need and budget. Properly panelizing your PCB designs with the help of capable software will save time, reduce costs, and ensure a smooth transition from design to mass production.