Leading the way for over 40 years
At Mer-Mar Electronics, we offer unstinting focus on quality when it comes to Prototype PCB Manufacturing. What is more, once your design is tested and you are ready to roll your full production run, we are as equipped to handle that.
If you are developing a new product, you need to make sure that your design works properly. That necessitates creating a prototype of your board, a small run to test functionality.
The many benefits of prototype PCB manufacturing include:
- Detecting design flaws early
- Ability to test multiple designs
- Quick turn around time
- Simplified testing and analysis cycle
- Ability to break up complex designs and test components individually
As a leading prototype PCB manufacturer and with over four decades of experience in prototype PCB manufacturing and assembly, you can count on our state-of-the-art equipment and experienced personnel to offer high quality PCBs. Irrespective of how complex your requirement may be, we can do justice to your project. Fast turnarounds to no minimum quantities are only some of the benefits we offer.
At Mer-Mar Electronics, our prototype PCB manufacturing is known for:
- Its strong design expertise and following design for manufacturing protocols.
- Functionally advanced designs that lend themselves to miniaturization.
- Manufacturing review and assistance.
- Turnkey services.
- Quick turnaround times.
- Robust testing.
Why is Mer-Mar Electronics your go-to place for Prototype PCB Manufacturing?
State-of-the-art facility – At Mer-Mar Electronics, we have the necessary technology that delivers prototype PCB manufacturing that are way ahead of the curve. Additionally, our experienced team is equipped with industry best practices that ensure that you do not have to reinvent the wheel.
Stringent manufacturing Processes – Strict adherence to industry best practices and standards ensures that you get best-in-class products. Our robust testing protocols have you totally covered.
Wide variety of boards – We can deliver virtually any type of PCB prototype, from single- and double-sided boards to complex multilayered ones. You can bank on us for rigid, flex as well as rigid-flex boards.
Quick turnaround time – With prototype PCB manufacturing, long delivery cycles are a strict no-no. We offer quick turnaround times that enable you to check the functionality of the board and make corrections wherever required. In turn, this means quick go-to-market.
Prototype PCB Manufacturing Services
PCB design services
Avail of our PCB design services that not only lend themselves to complexity of design and miniaturization, additionally we also ensure that the designs undergo strong design for manufacturing and assembly (DFMA) techniques.
Additive Manufacturing of PCB prototypes
Our additive manufacturing systems and processes ensure that we do justice to the most complex designs and fabricate multilayer PCBs with ease.
PCB Turnkey services
You can count on us for end-to-end Prototype PCB Manufacturing services. Among other things we can help you with component selection and procurement. Rest assured that your prototype PCB manufacturing is in capable hands.
PCB Production flexibility
Our Prototype PCB Manufacturing comes with no volume commitments. Additionally, when you are ready to get into a full production run, you get the same focus on quality and timeliness.
The broad stages involved in Prototype PCB Manufacturing span the following:
PCB Design & Schematic Design
Not only is it important to have an effective design, it is equally important to have a schematic design in place that includes information about the material, components, placement and more. Selecting the right panel size and grid goes a long way in the success of the PCB. The final design is then converted to a netlist. The entire design process involves running design rule checks at all stages.
Creation of Bill of Materials
THE BOM includes vital information such as the quantity of components, its reference designators, value, footprints, manufacturer part number and more.
Routing Design
This step is to do with designing the routing byway of traces. There are a number of factors that need to be taken into account at this stage including:
- Power levels
- Signal noise generation
- Noise sensitivity and more
Creating the Photo Film
With the design, a photo film, a sheet printed with a photo negative of the board is created. This marks the conductive and non-conductive parts.
Printing the Inner layers
Copper is now applied to the substrate material. Copper is first pre-bonded to the substrate after which a layer of photoresist is applied. It is then exposed top UV light to harden it. Nay unhardened photoresist is subsequently removed. Next the hardened photoresist is removed and the copper is seen in the exact spot it is meant to be.
Aligning the layers and fusing
If it is a multilayered PCB, the layers need to be aligned and holes need to be punched. The layers are next fused together. The prepreg and the substrate is covered by copper foil. The layers are fused through a process of layer-up and bonding.
Drilling of Holes
This involves precise drilling of holes. To do that an x-ray locator is first used followed by dexterous hole drilling.
Copper Plating
The next step involves depositing copper on the panel’s surface.
Outer Layer Imaging
A layer of photoresist is next applied to image the outer layers.
Copper and Tin Plating
Another round of copper plating follows. The photoresist layers ensure copper only deposits on the desired parts. This is typically followed by tin plating.
Final Etching
Any excess copper is removed at this stage. The tin plating continues to protect the copper.
Solder Mask
An epoxy solder mask ink is next applied after cleaning the panel. The board is then exposed to UV light. Any unhardened parts are subsequently removed.
Applying the Surface Finish
Appropriate surface finish is next applied in keeping with the environment the PCB has to function in.
Silkscreen and Cutting
Silkscreen is then applied to convey critical information. Next comes cutting the board using either a router or a v-groove.
Assembly
This process involves attaching the required components to the board.
Solder Paste Stenciling
Solder paste is applied to the board. A stencil is used so that the solder paste is applied only to the areas where components are to be attached.
Pick and Place
A pick and place machine helps place surface mount components on the board.
Reflow Soldering
This process solidifies the solder paste. In turn, it helps attach the components to the board.
Inspection and Quality Control
Errors if any, are checked for, after the reflow stage. Manual checks, AOI as well as X-ray inspection is carried out.
Functionality Test
The final step is a functionality test that simulates normal operating conditions.
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Prototype PCB Manufacturing Capabilities
| Features | Capability |
|---|---|
| Quality Grade | Standard IPC 1 |
| Build Time | 2 – 7 days |
| Material | FR-4 Standard Tg 140°C |
| Board Size | Min 6*6mm | Max 500*500mm |
| Board size tolerance | ±0.1mm – ±0.3mm |
| Board Thickness | 0.4mm – 2.0mm |
| Board Thickness Tolerance | ±0.1mm – ±10% of thickness of board |
| Copper Weight | 1.0oz – 2.0oz |
| Inner Layer Copper Weight | 0.5oz – 1.0oz |
| Copper Thickness Tolerance | +0μm +20μm |
| Min Tracing/Spacing | 5mil/6mil (copper weight: 1oz) 8mil/8mil (copper weight: 2oz) |
| Solder Mask Sides | As per the file |
| Solder Mask Color | Green, White, Blue, Black, Red, Yellow |
| Features | Capability |
|---|---|
| Silkscreen Sides | As per the file |
| Silkscreen Color | White, Black |
| Surface Finish | Lead Free HASL – RoHS HASL – Hot Air Solder Leveling ENIG – Electroless Nickle/Immersion Gold – RoHS |
| Min Annular Ring | 5mil |
| Min Drilling Hole Diameter | 8mil |
| Min Width of Cutout (NPTH) | 0.8mm |
| NPTH Hole Size Tolerance | ±.002″ (±0.05mm) |
| Min Width of Slot Hole (PTH) | 0.6mm |
| PTH Hole Size Tolerance | ±.003″ (±0.08mm) – ±.006″ (±0.15mm) |
| Surface/Hole Plating Thickness | 20μm – 30μm |
| SM Tolerance (LPI) | .003″ (0.075mm) |
| Aspect Ratio | 10:1 (board thickness: hole size) |
| Test | 10V – 250V, flying probe or testing fixture |
| Features | Capability |
|---|---|
| Quality Grade | Standard IPC 1 |
| Build Time | 2 – 7 days |
| Material | FR-4 Standard Tg 140°C |
| Board Size | Min 6*6mm | Max 500*500mm |
| Board size tolerance | ±0.1mm – ±0.3mm |
| Board Thickness | 0.4mm – 2.0mm |
| Board Thickness Tolerance | ±0.1mm – ±10% of thickness of board |
| Copper Weight | 1.0oz – 2.0oz |
| Inner Layer Copper Weight | 0.5oz – 1.0oz |
| Copper Thickness Tolerance | +0μm +20μm |
| Min Tracing/Spacing | 5mil/6mil (copper weight: 1oz) 8mil/8mil (copper weight: 2oz) |
| Solder Mask Sides | As per the file |
| Solder Mask Color | Green, White, Blue, Black, Red, Yellow |
| Silkscreen Sides | As per the file |
| Silkscreen Color | White, Black |
| Surface Finish | Lead Free HASL – RoHS HASL – Hot Air Solder Leveling ENIG – Electroless Nickle/Immersion Gold – RoHS |
| Min Annular Ring | 5mil |
| Min Drilling Hole Diameter | 8mil |
| Min Width of Cutout (NPTH) | 0.8mm |
| NPTH Hole Size Tolerance | ±.002″ (±0.05mm) |
| Min Width of Slot Hole (PTH) | 0.6mm |
| PTH Hole Size Tolerance | ±.003″ (±0.08mm) – ±.006″ (±0.15mm) |
| Surface/Hole Plating Thickness | 20μm – 30μm |
| SM Tolerance (LPI) | .003″ (0.075mm) |
| Aspect Ratio | 10:1 (board thickness: hole size) |
| Test | 10V – 250V, flying probe or testing fixture |
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Application of Prototype PCB Manufacturing
Prototype PCB Manufacturing seems wide application in the following use cases:
- New product development
- Testing for individual components
- Modeling or a visual representation of a design
- Minimum viable product for investor pitches
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Certifications
We follow the requisite industry standards like
- ISO 9001:2008 Certification
- IPC-WHMA-A-610 Compliant
- IPC-CC-830B Compliant
- SBA Certified
- IPC-A-610-D & ANSI/J-STD-001 standards
- ISO 9001: 2015 Certified
- ISO 13485: 2016 by Medical Devices Quality Management
- International Traffic in Arms Regulation Compliant (ITAR)
Prototype PCB Manufacturing FAQs
Are you looking for prototype PCB manufacturing services? Send us inquiry to Get a Quick Prototype PCB Manufacturing Quote based on your custom requirements.
If you have any queries regarding to our prototype PCB manufacturing services, new products prototyping, PCB prototyping services or need an urgent assistance, then please don’t hesitate to contact our team of skilled personnel’s. Send us an email with your queries at sales@mermarinc.com or call us at (760) 244-6149. We are looking forward to hearing from you.
