HDI PCBs refer to high-density interconnect PCBs in which the wiring density is higher as compared to other types of PCBs. Therefore, such PCBs are more complex and have intense applications in the PCB world. Since HDI PCBs are complex, you need to be extra precise with them as well. Kind of overwhelming to know this, isn’t it?
Well, you should not worry since HDI PCBs will be a no-brainer for you after reading this discussion. These are crucial when we talk about miniaturization because almost all small and portable devices contain HDI PCBs. These are also beneficial when it comes to keeping the performance of devices intact in the long run.
Wait, this is not all about HDI PCBs; these amazing circuit boards have a lot more to them. We are going to decipher HDI PCBs for you so that you can understand their functioning better.
What Is HDI PCB?
You already know what HDI means. These are different than other types of PCBs because of the wiring density. You will find excess wiring density in HDI PCBs. The electrical connections present in HDI PCBs are higher in amounts which means these have a distinctive structure, and their applications also depend on it as well.
Why are HDI PCBs Important?
Now we will take a look at some convincing reasons why you should use an HD PCB for your projects:
- Space efficient nature
- More lines and interconnects
- Relatively minor capture pads
- The connection density is higher
- Integration of small vias
- Supportive to laser drilling
- HDI PCBs need less space for assembly
Top Factors Affecting the Cost of HDI PCB Production
1. Design Complexity
By far, we know that the nature of HDI PCBs is complex, which makes them different from the pre-existing PCBs in the market. It also means that the performance of HDI PCBs depends on their designs.
If you overlook any fault in their designs, these will fail to work as per your expectations as well. Sometimes, you need to go beyond the regular production techniques of HDI PCBs. It usually happens because of their components. Due to this reason, these HDI PCBs are expensive, and their production budget is also higher than simple PCBs.
2. Layer Count
Complex PCBs have many layers. So do HDI PCBs. Their layer count is higher, which adds to their cost. Now you know producing HDI PCBs is not a piece of cake since many factors like layer count can make a dent in your pocket. More layers mean more production costs. Each layer just keeps adding to the complexity of HDI PCBs.
3. Materials & Substrates
You cannot develop an HDI PCB without materials and substrates. The core of HDI PCBs is their materials. Now not every HDI PCB can survive with affordable and accessible materials. Some need you to pull the strings and grab rare materials as well.
Now a rare material for HDI PCB means expense. Some materials are also hard to import; therefore, they also make HDI PCBs expensive to produce.
4. Via Types & Aspect Ratios
You already know what vias and aspect ratios for PCBs are. Well, things can be different when we consider these and can also disturb your production cost.
If you use regular techniques for making vias during the assembly, it won’t cost you much. However, the problem occurs when you are using some special methods for drilling vias. It will increase the cost, and the same applies to the aspect ratios.
5. Manufacturing Techniques
Producing a PCB is an extensive process. It has different steps that develop a PCB on many levels. Now these steps can be lamination and laser drilling. Wait, there are more steps in the process, but we are saving you time here by not mentioning all of them.
So these individual steps need your money as well. Thus, the cost also depends on the manufacturing you are going to follow in this regard. If you can produce an HDI PCB through an affordable method, then there is no harm in grabbing that option.
6. Production Volume
If you are a PCB producer, you need to be smart. Now how’s that possible? You need to look for bulk production of PCBs. When you do this, it will not increase the cost. You will import bulk materials for the production as well.
It is recommendable to do this instead of producing PCBs on a small scale. It also comes in handy when you don’t want to make a dent in your pocket. If you produce PCBs on a small scale, it will do nothing but increase the cost in the end.
7. Quality & Reliability Requirements
Imagine producing bulk PCBs and all of them are similar in one thing. DEFECTS! Yes, this can turn out to be a nightmare for you if you don’t inspect your PCBs. You can choose one inspecting method for PCBs and stick to it. Now here’s the stitch, not every inspecting technique is affordable. Therefore premium testing methods can also increase the product cost of HDI PCBs.
8. Component Density & Placement:
If you are using many components in PCBs, it will make them expensive. Because you need special assembling methods for them that might not be affordable.
9. Surface Finish:
Making your HDI PCBs premium has its cost. Yes, the surface finish you are using for your PCBs might be expensive, which will impact their cost. Mostly, silver and gold surface finishes are not affordable for manufacturers.
10. Specialized Features:
Some clients ask you to add special features to their HDI PCBs. It can be anything, including a controller or a tracker that will give an edge to the devices later. Now special features need different testing methods. So, it will increase the cost as well.
11. Certification & Compliance:
Nobody will trust your PCBs if you don’t test them before delivering. Therefore, inspecting your PCBs for your client’s safety and trust is important. For this, you also have to pay for the certifications and PCB testing methods.
12. Prototyping:
Complex PCBs like HDI PCBs need more workforce for production. It means you have to pay them as well. The result? Higher production cost! Similarly, advanced production equipment and prototyping result in an increase in the PCB cost.
13. Supply Chain Factors:
If you use a rare material for producing PCBs, it will also increase the budget because it is hard to find. Also, you might need to go above and beyond to get this material which can increase the PCB cost.
Conclusion
The PCB manufacturers have to be sure that they are using the right materials, production techniques, and PCB testing methods if they are on a tight budget. A little brainstorming, in the beginning can help save your business from a huge hit.
If there is a margin that you can use an affordable option in this entire scenario, then the wisdom is to grab this opportunity at once. We have discussed all these factors for you in this post. Hoping that you will be more aware while producing HDI PCBs after knowing the abovementioned factors!
