Rapid PCB Prototyping

Leading the way for over 40 years

Rapid PCB Prototyping

Rapid PCB Prototyping is an extremely important process that creates early functional replicas of a product. It serves the crucial need of testing and ratifying a product’s functional design. As a leading PCB manufacturer, at Mer-Mar Electronics, we offer quality rapid PCB prototyping services that offer a number of advantages including but not limited to:

Faster Lead times – With rapid PCB prototyping, quick turnaround is a given. By reducing the fabrication time, what it helps do is early testing and ratifying of the design. Any changes required thereafter can be quickly identified and early go-to-market is assured that can be a huge source of competitive advantage.

Accurate final product – With rapid prototyping, you have the ability to test every circuit design and function. This gives you a fair idea of how the final product will work. In case any changes are required in the layout for optimal functionality, they can be made early. What you are safeguarding yourself against are costly errors at a later stage.

Easy to make changes – With rapid prototyping, it is much easy to make any modifications with each iteration.

Small volume – A big advantage of going with Mer-Mar Electronics is that we cater to prototype quantities with the same attention to detail as we do with large production runs.

Quality Rapid PCB prototyping – With our state-of-the-art technology and experienced personnel that are armed with industry best practices, we offer quality PCB Prototypes after through testing, that ensure you get products that are ahead of the curve.

Cost reduction – Our PCB Prototypes enable you to reduce overall project cost as it helps find issues, if any, at early stages of the cycle. With the ability to fail faster you can improve your product to your satisfaction before it goes into final production. Rapid Prototyping also works extremely well for startups looking for funding and wanting to showcase a minimum viable product.

At Mer Mar Electronics our Rapid PCB Prototyping is known for:

  • PCB design iterations followed by strong design for manufacturing and assembly (DFMA) techniques.
  • You can count on us for quality part procurement at cost-effective rates
  • Simplification of the the assembly process
  • Functionally advanced designs that lend themselves to miniaturization

These go a long way in improving time to market as well as to develop a strong reputation in the market. A huge portfolio of clients who have used our services for their prototyping needs and then gone on to partner with us for large production runs, are testimony to our success.

Partner for Rapid PCB Prototyping

Superior facility – Our state-of-the-art manufacturing equipment as well as our engineering expertise enables us to produce the best quality prototypes that are significantly ahead of the curve. Our experienced staff is highly qualified and has a good hands-on experience in rapid PCB prototyping.

Adherence to strict industry standards – Strict adherence to industry best practices and standards ensures that you are assured of the quality. In addition, our robust testing protocols have you covered.

Quick turn around time – Rapid PCB Prototyping by its very name suggests early turnaround. Count on us to cater to prototype quantities with speed as well as efficiency. Go-to-market is now made easy!

Easy to scale up – Post the prototype stage when it is time for you to indulge in a full production run, you can count on us to offer the same efficiency and quality.

Rapid PCB Prototyping Services

Rapid PCB Prototyping

Design for Manufacturability

With PCB design having a huge role in overall performance, we offer robust design for manufacturability tests. This, in turn, ensures that your prototypes can move to final production with ease.

Rapid PCB Prototyping Service

Additive Manufacturing for Multilayer PCB

With our additive manufacturing systems and processes, you can rest assured that the most complex multilayer PCBs can be manufactured with ease. High component density and miniaturization are aspects that we deal with efficiently.

PCB Rapid Prototyping

Turnkey Services

From design to sourcing of parts, fabrication and assembly, you can bank upon us for turnkey PCB prototyping requirements. This ensures that you can focus on your core competencies while being sure that your PCB requirements are in good hands.

PCB Rapid Prototyping Service

On-demand manufacturing

Ensure you enjoy utmost production flexibility without binding yourself to many volume commitments. We offer on-demand manufacturing to suit your requirements. We can provide rapid PCB prototyping in 24 hours to 5 days lead time based on your requirements.

Rapid PCB Prototyping USA

System Integration

Whether your industry require a single prototype or a large-scale production, Mer-Mar Electronics is providing custom manufacturing and system integration with rapid turnaround time. We can be your one-stop shop for all your needs with components supply chain, parts procurement, device programming, PCB assembly, turnkey assembly, sub-assembly and even full box build assembly.

Rapid PCB Prototyping Process

The end-to-end rapid PCB prototyping process involves the following stages:

Schematic Design

The important aspects of this phase are the choice of the right panel size and grid. In addition, the schmatic design includes crucial information on the use ofcomponents. At the end of the first schematic, simulations using specialized tools are run so that any errors can be spotted. The design is then converted with a netlist.

Routing Design

Designing of the routing involves looking at various factors such as;

  • Power levels
  • Signal noise generation
  • Noise sensitivity, and more

The netlist is used at this stage to figure out optimal routes based on the number of layers and other factors.

The design stage also involves continuous checking for thermal issues such as heat spots. In addition, other checks involve:

  • Design rule check
  • LVs check
  • Electrical rule check
  • Antenna check
  • Other quality assurance checks

Creating the Photo Film

Using the design, a photo film of the PCB is created. It has markings for parts that are copper conductive and non-conductive.

Printing the Inner layers

Copper is now applied to the substrate and then a layer of photoresist is applied. This is hardened with UV light. Unhardened photoresist is then removed. This is followed by removing of the hardened photoresist.

Aligning the Layers and fusing them

If it is a multi layer PCB, the layers are aligned correctly. The layers are then fused in two stages- layer-up and bonding.

Drilling the Holes

Holes are next drilled into the stack. To target the correct hole location, an x-ray locater is used.

Copper Plating

This involves depositing a layer of copper on the panel surface. Precision is of importance in this stage.

Outer Layer Imaging

A layer of photo resist is applied to the panel to image the outer layers.

Copper and Tin Plating

Another round of copper plating is undertaken. The presence of the photoresist layer ensures that copper only deposits on the desired parts. This is followed by tin plating.

Etching

Any excess copper is removed. The tin plating, in turn, protects the copper.

Solder Mask

The panel is cleaned and solder mask is applied. UV light then hardens the film. Any unhardened parts are subsequently removed.

Surface Finish

The right surface finish, basis the environment in which the PCB has to function, is next applied.

Silkscreen

Silkscreen is then applied to the surface of the PCB. The writing conveys important information about the board.

Cutting

Post a final electrical test, the board is cut using a router or a v-groove.

Assembly

At this stage the required components are added to the board:

Solder Paste Stenciling

Application of solder paste is next carried out. A stencil is placed over the PCB so that the solder paste is only applied to areas where the components need to be affixed.

Pick and Place

A pick and place machine places surface mount components on top of the soldering paste.

Reflow Soldering

This process solidifies the solder paste by running the PCB through a reflow oven. The board is heated up and then cooled so that the SMDs are permanently attached to the board.

Inspection and Quality Control

The board is checked for any errors. These include:

  • Manual checks
  • Automatic Optical Inspections
  • X-Ray inspection
  • Testing for functionality and connection quality

Inserting Through-Hole Components

If the board requires plated through-hole components, they are plated at this stage. This cannot be done through soldering paste. This has to be done either through manual soldering or wave soldering.

Functionality Test

This is the final step that simulates the operating conditions that the PCB will be exposed to, to check efficacy.

In case multiple designs of the prototype PCB are available; it will also help to run identical tests and compare results. Detailed testing at this stage ensures there are minimal issues at a later stage. Once you are fully satisfied with the design, you are ready for a full production run.

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Rapid PCB Prototyping Capabilities

At Mer-Mar Electronics, our rapid PCB prototypes offer high quality at optimal costs. Our rapid PCB prototype capabilities, span the following:

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 Rapid PCB Prototyping

Rapid Prototyping PCBs

Rapid PCB Prototyping, on account of the advantages that it offers from quality control, error minimization and more, lends itself to use across a number of categories. Primary among them being:

  • Electronics
  • Medical Devices
  • Mission critical appliances
  • Startups
  • Renewable Energy
  • Telecommunication
  • Manufacturing

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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)

Rapid PCB Prototyping FAQs

Looking for rapid PCB prototyping from Mer-Mar Electronics? Send us inquiry to Get a Rapid PCB Prototyping Quote based on your custom requirements.

If you have any queries regarding to our rapid 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.