The first questions that comes up is: How much will PCB assembly cost? The answer is — it depends.
At Poly Electronics, we know that every project is different. PCB assembly pricing is influenced by a number of variables including design complexity, volume, sourcing, and lead times. In this post, we’ll break down the key cost factors so you can better plan your next build and get the most value from your contract manufacturing partner.
1. Board Complexity and Size
The complexity of your PCB layout directly impacts cost. A small single-sided board is much easier and cheaper to assemble than a large, densely populated multilayer board.
Key drivers:
- Number of layers
- Board dimensions
- High pin-count components (e.g., BGAs, QFNs)
- Fine pitch parts that require advanced placement or inspection
- Mixed technologies (SMT + through-hole)
At Poly Electronics, we use advanced SMT lines and X-ray inspection equipment to handle complex boards efficiently — but complexity always adds to the time and care needed, and that translates into cost.
2. Component Sourcing and Availability
Component cost and availability can vary dramatically. You can supply your own components (consignment), or we can handle sourcing for you (turnkey or partial turnkey). In today’s global supply environment, lead time and part shortages can influence both cost and production timelines.
Tips to control costs:
- Choose common, well-supported components
- Provide an accurate and approved BOM
- Allow flexibility with alternates or second-source components
We work closely with vetted suppliers to ensure the best pricing and lead times while maintaining traceability and quality.
3. Assembly Volume
One of the biggest price variables is how many units you’re building. Low-volume, high-mix production has a higher cost per unit than high-volume runs because setup and programming costs are spread over fewer pieces.
Economies of scale kick in at higher volumes — and at Poly Electronics, we can scale with your product from early-stage prototype to full production.
4. Type of Assembly Services
PCB assembly can include:
SMT (Surface Mount Technology)
Through-Hole Insertion
Mixed Technology Assembly
Conformal Coating
Testing & Inspection (AOI, X-ray, functional testing)
The more services your project requires, the more labor and equipment are involved. For example, BGA assembly with X-ray inspection will cost more than standard SMT placement.
We offer a full suite of in-house testing options to ensure product reliability — and we’ll only recommend the ones your design actually needs.
5. Testing Requirements
Some customers require 100% functional testing, ICT, or custom fixture builds — all of which add value but also increase cost. Others may only need basic visual or AOI inspection. The key is aligning the level of testing with the risk and end-use of the product.
We’ll help you assess what makes sense for your application, whether it’s industrial, consumer, medical, or military.
6. Lead Time and Delivery Requirements
Rush jobs or quick-turn builds typically cost more. That’s because expedited production requires premium labor time, priority scheduling, and sometimes faster (and more expensive) component sourcing.
If you’re on a tight timeline, let us know early. We can often offer tiered pricing options based on standard and expedited delivery schedules.
Average PCB Assembly Cost Ranges (Estimates)
While every project is unique, here’s a very rough guide for U.S.-based PCB assembly:
| Assembly Type | Volume | Cost per Unit (Estimate) |
|---|---|---|
| Simple SMT, 2-layer | 100–500 units | $10 – $30 |
| Complex SMT, 4-layer | 100–500 units | $30 – $75 |
| Mixed SMT/Through-Hole | 50–200 units | $40 – $100+ |
| Low-volume prototypes | 1–25 units | $50 – $200+ (setup inclusive) |
Note: These estimates include assembly only and not PCB fabrication or component costs. We’ll provide accurate pricing once we review your BOM, Gerber files, and volume requirements.
How to Get an Accurate Quote
The best way to understand your cost is to request a formal quote. To speed up the process, be sure to include:
BOM with part numbers and approved alternates
Gerber files and assembly drawings
Quantity and delivery timeline
Special requirements (e.g., testing, conformal coating, packaging)
At Poly Electronics, our quoting process is fast, transparent, and collaborative — we’ll work with you to identify cost-saving opportunities without compromising on quality or performance.
Ready to Start Your Next Build?
Whether you’re developing your first prototype or scaling to high-volume production, Poly Electronics is your partner in precision, reliability, and flexibility. We’re committed to helping you deliver your products on time and on budget.
📞 Contact us today for a custom PCB assembly quote, or explore more about our capabilities here.
