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PCB Cost Optimization

We can review an existing product or design and propose methods for cost reduction. In many cases, layer reduction can be achieved by using smaller geometries for conductors and vias and the use of laser-drilled microvias.

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  • Material selection
  • Board size
  • Trace and space
  • Processes

A few factors can increase the cost of PCB manufacturing. Our design engineering team will take a closer look at your project and identify the areas of improvement.


We review the selected PCB materials and suggest lower-cost options based on the board’s functionality and application.

  • For frequencies less than 1 GHz, FR4 is recommended.
  • For frequencies from 1 to 5 GHz, materials such as I-speed are suggested.
  • For RF signals, special RF materials such as the Rogers 3000 series are suggested.


Another factor that drives up the manufacturing cost is the use of thinner traces and spaces. Below 4 mils, our production team will have to closely monitor your board fabrication, which will result in a more expensive PCB.

From a cost optimization standpoint, your traces and spaces should be greater than 4.25 mils.


When it comes to component cost reduction, we must analyze the types of components originally selected. We see on a regular basis customers going for higher-precision components, which are costlier, when cheaper alternatives are available.

  • Don’t choose pricey mil-spec components if your application does not require military-grade specifications.
  • Redundant components could also be identified. For instance, we often see designs with two resistances performing the same functions, such as I2C communication, you may have multiple pull up resistance on the SDA and SCLK signals. The extra resistances could be removed.




  • Since we have considerable experience in dealing with PCB materials, fabrication and assembly processes, as well as components, we know which areas of your design can be improved to drive the price down. Plus, due to the close interaction between our layout and manufacturing teams, we can ensure a quality board free of rework costs.
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Other Ways Sierra Circuits Can Help

We have many resources designed to help you, no matter where you are in your journey to becoming a PCB expert.

PCB Manufacturing& Assembly Processes

Knowing how your boards are manufactured and assembled will help you design boards that are cost-effective and technically robust.

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