Production Studio
Taking Your PCB Prototypes into High-Volume Production
The major difference between PCB prototypes and their production versions is that a production board is past testing and ready to be inserted into a finished, saleable product. As such, the requirements for building production boards are more defined than PCB prototypes. Most manufacturers will accommodate this increased thoroughness by assigning you a customer service representative instead of the usual do-it-yourself nature of ordering PCB prototypes.
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Understanding the different needs in design skills, parts requirements, and equipment for the two processes is very useful in getting the most out of each. For PCB prototypes, speed is usually the most important factor. Getting a workable and testable prototype as quickly as possible is important to electronic manufacturers and hobbyists alike. The desire to test designs as quickly as possible is only natural.
Moving from PCB Prototypes to Production
When moving to full-scale production runs of hundreds or even thousands of boards, quality and repeatability become the top concerns. This means that the quality of board number one must be exactly the same as the quality of board number 1,000, 10,000 or more. The need for this consistent quality means that manufacturers require more information from designers when going into high-volume production runs.
Manufacturers will ask you for:
- Bill of Materials - The BOM should include your part number, the part manufacturer’s name, the manufacturer’s part number, a reference designator, product description, and footprint
- Gerbers - You will need to send all of the Gerber files generated by your CAD program. At minimum, you must include the silkscreen, copper, and solder paste layers for your PCB
- Assembly Instruction Drawings - These additional assembly instruction are very useful in communicating any special PCB assembly instruction; however, they are not necessary
The manufacturer will also use an enhanced documentation process to ensure their ability to consistently reproduce your designs for large-volume production runs.
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Pilot Production or First Article Approval for PCB Prototypes
Manufacturers often call pilot production first article approval. Either way, it is an important step in transitioning from PCB prototypes to production runs. They help manufacturers determine whether or not your PCB prototypes are capable of being manufactured on a large scale. A PCB fabricator should use pilot production as a routine practice to ensure the high-quality, low-cost needs of large-volume production runs.
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