Printed circuit boards are important parts of modern electronics. They influence the quality and performance of electronic devices. But before going to full production, it is necessary to prototype.
PCB prototyping is becoming a fast emerging trend due to its numerous benefits. A prototype helps the business save on cost, time, and resources. For people starting from scratch, this is the best trend to follow. Below are some of why PCB prototyping has become an engorging trend.
What is PCB prototyping?
A prototype is an early sample of a product. The main purpose of prototyping is to test the idea to see whether it works well before full production. Hence, prototypes are made to test the functionality of the design.
Testing the design before actual manufacturing ensures no errors and the product can function properly. Small mistakes can easily go undetected, and some faults are invisible to the naked eye.
Different types of prototyping are used to test different aspects of design. For example, a design team can use multiple PCBs at several stages of the designing process.
Different types of prototyping
Visual models – are used to show the physical aspects of the circuit board design. The models show the entire shape and component structure. They are the prototypes in the process and are used to review the design easily and affordably.
Proof-of-concept prototypes – these are simple prototypes that focus on duplicating the board’s main function. The main work of a proof-of-concept prototype is to tell whether the design concept is practical.
Working prototype – this prototype contains the planned structures and functions of the final product. Its main work is to identify weaknesses or issues in the design. It represents what the finished product looks like.
Functional prototype – these prototypes are close to the final product. They provide an accurate idea of how the design will look and work.
Why do most businesses prefer prototyping?
Nowadays, most businesses choose rapid prototyping instead of going straight into the standard production. This is because the process has numerous benefits.
For instance, the process is used throughout the designing process to test the functionality of their product. Even though prototyping seems to add more steps and costs to the PCB manufacturing process, it helps identify errors and make changes before the final production.
The process helps the designers test the design at multiple stages and make relevant adjustments before full production. Some of the benefits of PCB prototyping for the clients and designers include:
1. Reduces timeline
Designers go through several repetitions when creating a PCB design before developing the final product. Although it can bring lengthy timelines, prototyping can speed the manufacturing process in the following ways.
*Complete testing helps the design team test the design and spot any problem quickly. Thus, there is no guesswork with this process. Without the design going through, sporting errors would take more time, leading to a longer timeline and more expenses.
*Visual assistance – many clients would like to see the product at several stages during production. Fortunately, prototypes offer visuals that can communicate well to the clients. This reduces the time mostly spent on explanations and requested redesigns.
*Reduced rework – prototyping allows you to test the circuit board before the full production run. If there are errors, you will have a chance to correct them on time. But if a faulty product goes to production, the rework will take longer, and it may cost more money.
2. Accurate and reliable prototype
With an accurate and reliable prototype, it is simpler to solve any design problem during the development process. Prototyping helps the designers to identify a problem during manufacturing. Thus, it helps in reducing the costs and project timeline.
Also, what works, in theory might not work well in practice. But with a prototype, you can assess the theoretical values of the board to tell if they show up in the practical values.
3. Reduced costs
A standard PCB product can be costly if you must redesign it. However, prototypes are vital for reducing production costs. For instance, the sooner the development team identifies a fault, the sooner they can fix it.
But if the issues go all the way to full-scale production, they are likely to destroy the production budget. In addition, PCB prototyping allows the designers to try different materials, assembly methods, and other approaches.
4. Test components individually
Designers use PCB prototypes for testing singular functions and components. Testing can be done for many purposes, including testing design theories and breaking down complicated designs.
Hence, individual testing allows PCB designers to test various functions effectively without ordering a whole PCB.
5. Manufacturing review
Designing errors and other problems that designers can miss can be identified through prototyping. Hence, it helps to develop a more effective product than before.
Remember, designers are humans who can make mistakes as well. Hence PCB prototyping is a great opportunity to identify the smaller faults that might have been missed.
Bottom-line
The PCB prototyping process is an important step that determines whether the final product will work as expected or not. It is an important stage that helps to reduce manufacturing costs by identifying and fixing errors before the final production run.
It also helps to tell whether product adjustments are needed early on, giving room for enhanced planning for the product. Thus, it has become an emerging trend in PCB production.
