Small-Batch PCB Costs Too High? 3 Strategies to Cut Expenses by 50%
- SUNSOAR TE.
- 23 hours ago
- 2 min read
If you’ve ever tried ordering small-batch PCB production, you’ve probably been hit with surprisingly high quotes — sometimes even higher per piece than mass production. Frustrating, right?
But here’s the truth: you’re not overpaying because of greed from suppliers — you’re overpaying because of the wrong strategy.
Let’s explore three proven ways to cut small-batch PCB costs by up to 50% — without compromising quality or delivery time.
Why Are Small-Batch PCBs So Expensive?
Simple: most PCB factories are optimized for high-volume runs. When you order 10 or 50 pieces, the setup cost (tooling, engineering, machine prep) is spread over fewer boards — meaning a higher cost per unit.
But there’s good news: smart sourcing and design decisions can change the equation in your favor.
Strategy 1: Panelize Your PCB Designs
If you’re ordering 10 boards that are small in size (say 30x50mm), don’t let the factory handle panelization — do it yourself!
✅ Why it works:Factories charge extra for setup and routing. By combining multiple boards into one panel:
You pay setup cost once
Reduce routing time
Maximize material usage
💡 Some of our clients have saved 20–30% just by panelizing smartly.
Strategy 2: Work with a True Factory — Not a Middleman
Many platforms and “PCB suppliers” online are just trading companies. They mark up the price, adding a layer of cost for no extra value.
✅ How to avoid this:
Ask for factory photos/videos or certifications
Check if they offer engineering support directly
Confirm they can handle DFM (Design for Manufacturability) checks in-house
💬 At Sunsoar, we own our production lines in Shenzhen. That means no markup, faster quotes, and real-time production feedback — all helping you save up to 30% instantly.
Strategy 3: Optimize Your BOM and Assembly for Cost Efficiency
If your small-batch order includes PCBA (assembly), be aware: the component sourcing strategy makes a huge difference.
✅ Our tips:
Choose in-stock parts from LCSC, Mouser, or Digi-Key to avoid MOQ issues
Allow equivalent part substitution when available
Use combined orders to reduce part sourcing overhead
🧠 Bonus: We help you replace costly modules with 16-year proven alternatives — saving hardware startups hundreds per build.
Real Client Example
A European IoT startup came to us with a prototype order of 50 PCBA units. Their previous supplier quoted $1,180.
By panelizing the boards, optimizing the BOM, and eliminating broker fees, we brought the cost down to $648 — a 45% reduction, delivered in just 8 working days.
Final Thought: Small Batch ≠ Small Savings
With the right strategy, small-batch PCB projects don’t have to hurt your wallet. You just need a partner who’s willing to go the extra mile — and thinks like a hardware startup, not a mass production line.
📩 Ready to cut your next order cost by half? Send your design file and BOM — and we’ll offer a free cost-saving audit.
Comments