Prototype PCB Manufacturing

Leading the way for over 40 years

Prototype PCB Manufacturing

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

Prototype PCB Manufacturing

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.

Prototype PCB Manufacturing Service

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.

Prototype PCB Manufacturer

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.

Prototype PCB Manufacturers

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.

Prototype PCB Manufacturing Process

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
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 Manufacturer USA

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

ISO 9001:20015 Logo Itar Logo

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.