1, Cost composition
The total cost of prototype processing usually includes the following main parts:
Engineering cost:
Design fees: The work of design engineers is charged by the hour, and the specific fees are influenced by factors such as work location, work experience, education level, and professional field. The design cost of complex products can reach hundreds of thousands or even millions of yuan.
Software tool cost: The cost of using design software such as CAD, CAM, etc.
Material cost:
Printed Circuit Board (PCB): The cost of a PCB depends on its size, number of layers, material type, and production process. For example, the cost of four layer boards is higher than that of two layer boards, and the use of advanced technologies such as blind holes and buried holes will also increase costs.
Electronic components: Although the cost of a single electronic component is relatively low, it can also become a cost item that cannot be ignored when used in large quantities.
Shell material: including plastic, metal, etc., the cost depends on the material type, thickness, processing difficulty, etc.
Processing cost:
PCB manufacturing: including processes such as circuit board production, testing, and lamination.
SMT surface mount processing: electronic components are mounted onto a PCB, and the cost is calculated based on the number of points, with each point costing between 0.01-0.015 yuan.
DIP plug-in processing: Insert plug-in components into the PCB, and the cost is also calculated based on the number of points.
Assembly cost: Assemble PCB, shell and other components into a complete product.
Testing cost:
PCBA testing: including testing labor costs, fixture costs, and auxiliary material costs.
Functional testing: Verify whether the various functions of the product are normal.
Other costs:
Mold cost: When mass producing shells, it may be necessary to open molds, which incurs high costs.
Test rack cost: equipment used for batch testing of PCBs or products.
Logistics cost: The cost of transporting the prototype from the processing plant to the customer or testing site.
2, Cost estimation method
PCB cost estimation:
Small batch: Calculated by size price, the manufacturer will provide a unit price per square centimeter based on the number of layers and process of the PCB. Customers only need to convert the size of the PCB into centimeters and multiply it by the unit price to obtain the unit price of the PCB they need to produce.
Large scale: Calculated based on cost refinement prices, including material costs, labor costs, profits, etc.
Component procurement cost:
Purchase the required components according to the BOM list, considering a material loss increase of about 5%.
Usually, PCBA assembly and processing manufacturers have long-term cooperative component suppliers with relatively lower prices.
SMT surface mount processing cost:
Calculate the number of points multiplied by the unit price of the points, and the unit price of the patch points is between 0.01-0.015 yuan.
The point calculation is based on 2 pins per point for SMT surface mount materials and 1 pin per point for DIP plugins.
Assembly and testing costs:
The assembly cost depends on the complexity and difficulty of the product assembly.
The testing cost includes testing labor cost, fixture cost, and auxiliary material cost.
Mold and testing rack costs:
The cost of the mold depends on the size, complexity, and required number of parts of the shell.
The testing rack fee is used for batch testing of PCBs or products.
3, Strategies to reduce costs
Simplify the product: Simplify the product as early as possible, as seemingly "simple" features often greatly increase the complexity and cost of development.
Optimization design: By optimizing PCB design, such as reducing the number of layers and optimizing wiring, manufacturing costs can be reduced.
Choose suitable materials: while meeting performance requirements, choose materials with lower costs.
Batch procurement: By purchasing components and raw materials in bulk, more favorable prices can be obtained.
Improve production efficiency: Adopt advanced production processes and equipment to enhance production efficiency and reduce processing costs per unit of product.
