Designing a PCB panel isn’t just about grouping individual boards together — it’s about optimizing your production process, reducing waste, and ultimately saving money. Whether you’re a design engineer working with prototypes or a buyer managing large-volume production, understanding how PCB panel design works is key to achieving better yield, smoother assembly, and lower costs per unit.
This guide will walk you through every aspect of PCB panel design — from terminology to real-world methods, pricing factors, software tools, and expert tips. Whether you’re new to panelization or looking to improve your current process, this comprehensive guide will equip you with the practical knowledge you need.
1. Introduction to PCB Panel Design
PCB panel design is a critical step in the manufacturing process, allowing multiple individual PCBs to be grouped together into a single panel. This technique, known as panelization, improves production efficiency and reduces overall costs. Panelized PCBs are commonly used in high-volume manufacturing and SMT assembly processes.
2. Key Terminologies in PCB Panelization
Before diving into design practices, it is essential to understand some key terms:
- Single PCB: A standalone printed circuit board.
- Panel: A group of PCBs arranged together in a larger board for mass production.
- V-groove: A V-shaped cut used for easy board separation.
- Breakaway tabs: Small sections connecting boards with perforations or mouse bites.
- Fiducials: Markers used for alignment during SMT assembly.
- Tooling holes: Holes for alignment and fixing during the fabrication process.
3. Benefits of PCB Panel Design
Proper PCB panelization brings several benefits:
- Improved Manufacturing Efficiency: Multiple boards can be fabricated and assembled simultaneously.
- Cost Reduction: Shared tooling and materials lower per-unit costs.
- Streamlined Assembly: Automated machines handle panels more easily than single boards.
4. Common Panelization Methods
There are several panelization methods used depending on the board and assembly type:
- V-Scoring (V-Cut): Boards are partially cut with a V-groove, ideal for rectangular shapes.
- Tab-Routing: Boards are connected by tabs with or without perforations; suitable for irregular shapes.
- Mixed Techniques: Combination of V-scoring and tab-routing for complex panel designs.
5. Design Guidelines for Effective Panelization
To ensure a successful PCB panel design, consider the following guidelines:
- Standard Panel Sizes: Use standard sizes like 18×24 inches to match manufacturing equipment.
- Component Placement: Avoid placing components close to edges or break lines.
- Clearance: Maintain proper spacing between boards and panel edges.
- Fiducials and Tooling Holes: Place fiducials on the panel frame and ensure tooling holes match factory standards.
6. Panel Design for Different PCB Types
Different PCB materials and structures may require unique panel designs:
- Rigid PCBs: Most compatible with V-scoring and tab-routing.
- Flexible PCBs: Require custom panel frames and carriers for support.
- Aluminum/IMS PCBs: Often routed individually due to cutting challenges.
7. Cost Considerations in Panel Design
Panelization can significantly affect manufacturing costs:
- Material Utilization: Optimizing layout reduces waste and cost.
- Assembly Time: Efficient panel designs speed up SMT assembly.
- Shipping and Handling: Larger panels may reduce packaging and handling costs.
As a general reference, here are sample prices:
- Single 4-layer board (100mm x 100mm): ~$1.20 each in low volume
- Panelized (10-up) in 18″ x 24″ format: ~$0.85 or less per board at mid-volume (1000+ units)
- Panel tooling setup: $50–$150 one-time charge, depending on manufacturer
- Cost savings: Up to 25–35% per unit with optimized panel layout
8. Common Mistakes in PCB Panel Design
Avoid these typical errors:
- Insufficient Clearance: Can cause shorts or damage during depaneling.
- Poor Tab Placement: May result in breakage or rough board edges.
- Missing Fiducials: Leads to alignment issues during assembly.
9. Tools and Software for PCB Panel Design
Popular tools for panel design include:
- Altium Designer: Advanced features for automated panelization.
- KiCad: Open-source solution with manual panel creation.
- EasyEDA: User-friendly online tool for basic panel layouts.
10. Final Tips from a PCB Manufacturer
- Consult Early: Discuss panelization needs with your PCB manufacturer before finalizing the design.
- Follow Guidelines: Adhering to fabrication and assembly specs reduces delays.
- Prototypes First: Test your panel design with a small batch to verify quality.
11. FAQs About PCB Panel Design
Q: What is the ideal panel size for production?
A: Most manufacturers prefer panels up to 18×24 inches for efficient processing.
Q: Can flexible PCBs be panelized?
A: Yes, but they require support frames or carriers.
Q: Does panelization affect lead time?
A: A well-designed panel may reduce overall lead time by simplifying production.