PCBgogo

In today's era of rapid iteration in electronics development, small-batch, multi-lot prototyping and trial production have become the norm for many small and medium-sized enterprises (SMEs) and startup teams. However, this has also brought a series of cost control challenges: high unit costs, material waste, and repeated mold opening issues are becoming increasingly prominent.

We have gradually developed a set of cost optimization ideas for small-batch, multi-lot production through multiple projects. Here are a few key points to share with you today:

1. Design Phase: Tailoring for "Small-Batch" Production

Many designers are accustomed to using large-batch thinking for component selection and BOM configuration, neglecting the procurement logic in a small-batch environment. For example, using obscure packaging or extremely small resistor specifications may double the material purchase price. It is recommended to prioritize the selection of common packaging and material numbers with stable spot supply from the beginning. PCBGOGO's BOM optimization suggestion service can prompt high-cost, long-lead-time components when submitting the initial list, effectively avoiding the time loss caused by repeated material changes.

2. Prototyping Strategy: High Coordination Between Batches

The small-batch, multi-lot production model means long project cycles and frequent iterations. If each batch starts from scratch, not only is the communication cost high, but it also leads to repeated investment in test fixtures and packaging materials. We suggest adopting a "main version + minor iteration" approach for prototyping, where stable modules are frozen in advance and version control is applied to the debugging parts.

3. Panelization Strategy: Reducing Hidden Costs

Without panelization, the unit board cost is often high in small-batch production. However, random panelization can easily lead to rework due to insufficient space for flying leads and blocked test points. Our approach is to establish a fixed "panelization standard template," controlling variables through unified process requirements and sharing the template with the manufacturer to reduce explanation costs. PCBGOGO has a high degree of compatibility in this regard. Its engineering support team can assist in judging the rationality of panelization design and provide modification suggestions, compressing the chances of rework from the source.

4. Testing and Packaging: Reusability is Key

Multi-lot production can easily lead to significant one-time investments in testing and packaging. It is recommended to design reusable test fixtures and even consider standardizing test point layouts during the initial evaluation. Additionally, materials such as anti-static packaging and tray storage can be reused through a recycling mechanism between the manufacturer and the customer to reduce long-term costs.

5. Balancing Time and Cost: Don't Sacrifice Pace for Savings

The last piece of advice is: don't solely pursue the lowest quote while ignoring the cost of lead time and service response speed. Small-batch production often has a tight schedule and is more prone to changes. Timely response is more valuable than just a low price. In this regard, PCBGOGO's prototyping lead time and customer response speed are the main reasons our team repeatedly collaborates—quick feedback and engineering support can save not only working hours but also an entire project window.

In summary, although small-batch, multi-lot PCBA projects have slightly higher unit prices, as long as the rhythm is well managed and collaboration is optimized, it is entirely possible to achieve a win-win situation of "flexibility + efficiency." Cost control is not about bargaining but about reducing costs and increasing efficiency through systematic optimization. We hope this set of methods will inspire your projects.