Printed Circuit Boards (PCBs) are the backbone of modern electronics, serving as the foundation for almost every electronic device we use today. Whether you’re a hobbyist, an engineer, or a business owner, there may come a time when you need to reorder previously designed PCBs or assembled PCBs. However, one of the most significant costs associated with PCB manufacturing is the tooling cost, which can be a barrier for small-scale production or prototyping. Fortunately, there are ways to reorder your previous PCBs or assembled PCBs without incurring additional tooling costs. This article will explore these methods in detail, providing you with actionable insights to save money while maintaining the quality of your PCBs.

Understanding Tooling Costs in PCB Manufacturing

Before diving into how to avoid tooling costs, it’s essential to understand what tooling costs are and why they exist in the first place.

What Are Tooling Costs?

Tooling costs in PCB manufacturing refer to the expenses associated with creating the necessary tools, molds, and fixtures required to produce a specific PCB design. These costs typically include:

1. Phototools: These are the films or digital files used to transfer the PCB design onto the copper-clad laminate.
2. Drill Files: These files contain the information needed to drill holes in the PCB for vias, through-holes, and mounting points.
3. Stencils: Solder paste stencils are used to apply solder paste to the PCB before component placement.
4. Test Fixtures: These are custom fixtures used to test the functionality of the assembled PCB.

Why Do Tooling Costs Exist?

Tooling costs exist because each PCB design is unique, requiring custom tools and setups to manufacture. These costs are typically one-time expenses incurred during the initial production run. However, if you need to reorder the same PCB design, you may not need to pay these costs again, provided that the manufacturer still has the necessary tools and files on hand.

How to Reorder PCBs Without Tooling Costs

Now that we understand what tooling costs are, let’s explore how you can reorder your previous PCBs or assembled PCBs without incurring these costs.

1. Reordering from the Same Manufacturer

The most straightforward way to avoid tooling costs when reordering PCBs is to use the same manufacturer that produced your initial batch. Here’s why:

• Existing Tooling: If you’re reordering the same PCB design, the manufacturer likely still has the phototools, drill files, stencils, and test fixtures from your initial order. This means they won’t need to create new tools, saving you the tooling cost.
• Established Relationship: Working with the same manufacturer also means they are familiar with your design requirements, reducing the risk of errors and ensuring consistent quality.

Steps to Reorder from the Same Manufacturer:

1. Contact the Manufacturer: Reach out to the manufacturer and provide them with your previous order number or design files. This will help them locate the existing tooling and files.
2. Confirm Availability: Ensure that the manufacturer still has the necessary tools and files. If they do, you can proceed with the reorder without additional tooling costs.
3. Place the Order: Once everything is confirmed, place your order. Be sure to specify that you are reordering the same design to avoid any confusion.

2. Using Gerber Files from Your Initial Order

If you need to switch manufacturers or if your original manufacturer no longer has the necessary tools, you can still avoid tooling costs by providing the new manufacturer with the Gerber files from your initial order.

What Are Gerber Files?

Gerber files are the standard file format used in PCB manufacturing. They contain all the necessary information about the PCB design, including the copper layers, solder mask, silkscreen, and drill data. These files are used to create the phototools and drill files needed for production.

Steps to Reorder Using Gerber Files:

1. Locate Your Gerber Files: If you have the Gerber files from your initial order, you can provide them to the new manufacturer. These files should include all the necessary layers and drill data.
2. Verify the Files: Before sending the files to the manufacturer, verify that they are complete and accurate. Missing or incorrect files can lead to production delays and additional costs.
3. Send the Files to the Manufacturer: Once you’ve confirmed that the Gerber files are correct, send them to the new manufacturer. They will use these files to create the necessary tools and start production.
4. Confirm No Tooling Costs: When discussing the order with the new manufacturer, confirm that they will not charge tooling costs since you are providing the Gerber files.

3. Using a PCB Manufacturer with No-Tooling-Cost Policies

Some PCB manufacturers offer no-tooling-cost policies for reorders, especially if you are reordering the same design. These manufacturers understand that tooling costs can be a barrier for small-scale production and are willing to waive these costs to retain your business.

How to Find Manufacturers with No-Tooling-Cost Policies:

1. Research Online: Look for PCB manufacturers that advertise no-tooling-cost policies for reorders. Read reviews and testimonials to ensure they are reputable.
2. Contact Manufacturers Directly: Reach out to potential manufacturers and ask about their policies regarding tooling costs for reorders. Some manufacturers may not advertise this policy but may be willing to waive tooling costs for repeat customers.
3. Compare Quotes: Once you’ve identified a few manufacturers with no-tooling-cost policies, compare their quotes to ensure you’re getting the best deal.

Benefits of Using a Manufacturer with No-Tooling-Cost Policies:

• Cost Savings: By avoiding tooling costs, you can significantly reduce the overall cost of your PCB order.
• Consistency: Reordering from the same manufacturer ensures consistent quality and reduces the risk of errors.
• Convenience: Working with a manufacturer that offers no-tooling-cost policies simplifies the reordering process, saving you time and effort.

4. Using Modular or Panelized PCB Designs

Another way to avoid tooling costs when reordering PCBs is to use modular or panelized PCB designs. These designs allow you to produce multiple PCBs on a single panel, reducing the need for custom tooling.

What Are Modular or Panelized PCB Designs?

Modular or panelized PCB designs involve creating a larger PCB panel that contains multiple copies of the same PCB design. This approach is commonly used in mass production but can also be beneficial for small-scale reorders.

Steps to Reorder Using Modular or Panelized Designs:

1. Design the Panel: If you have the capability, design a panel that contains multiple copies of your PCB. This can be done using PCB design software.
2. Provide the Panel Design to the Manufacturer: Send the panel design to the manufacturer. They will use this design to create the necessary tools and produce the panel.
3. Separate the PCBs: Once the panel is produced, you can separate the individual PCBs. This can be done manually or using a depaneling machine.

Benefits of Using Modular or Panelized Designs:

• Reduced Tooling Costs: By producing multiple PCBs on a single panel, you can spread the tooling cost across multiple units, reducing the cost per PCB.
• Faster Production: Panelized designs allow for faster production since multiple PCBs are produced simultaneously.
• Consistency: Producing multiple PCBs on a single panel ensures consistent quality across all units.

5. Using Standardized PCB Designs

If you’re designing a new PCB and anticipate the need for future reorders, consider using standardized PCB designs. Standardized designs use common sizes, shapes, and hole patterns, making it easier to reorder without incurring additional tooling costs.

What Are Standardized PCB Designs?

Standardized PCB designs follow industry-standard specifications for size, shape, and hole patterns. These designs are often based on common form factors, such as Arduino shields or Raspberry Pi HATs, and are widely supported by PCB manufacturers.

Steps to Reorder Using Standardized Designs:

1. Choose a Standardized Design: When designing your PCB, choose a standardized form factor that is widely supported by PCB manufacturers.
2. Design the PCB: Create your PCB design based on the chosen standardized form factor. Be sure to follow the manufacturer’s guidelines for hole patterns and dimensions.
3. Reorder the PCB: When it’s time to reorder, provide the manufacturer with the standardized design. Since the design follows industry standards, the manufacturer may not need to create custom tools, saving you the tooling cost.

Benefits of Using Standardized Designs:

• Lower Tooling Costs: Standardized designs are often supported by existing tooling, reducing or eliminating the need for custom tools.
• Faster Turnaround: Since the design follows industry standards, the manufacturer can produce the PCB more quickly.
• Compatibility: Standardized designs are compatible with a wide range of components and enclosures, making them easier to integrate into your project.

6. Negotiating Tooling Costs with the Manufacturer

If you’re unable to avoid tooling costs entirely, you may be able to negotiate with the manufacturer to reduce or waive these costs. Many manufacturers are willing to work with customers, especially if you are placing a large order or are a repeat customer.

Tips for Negotiating Tooling Costs:

1. Leverage Your Order Volume: If you’re placing a large order, use this as leverage to negotiate lower tooling costs. Manufacturers are often willing to reduce or waive tooling costs for large orders.
2. Highlight Your Repeat Business: If you’re a repeat customer, remind the manufacturer of your loyalty and ask if they can waive or reduce the tooling cost for your reorder.
3. Compare Quotes: If you’re working with multiple manufacturers, use the quotes you receive to negotiate better terms. Let the manufacturer know that you are considering other options and ask if they can match or beat the competition.
4. Ask for a Discount: Don’t be afraid to ask for a discount on tooling costs. Many manufacturers are willing to offer discounts to secure your business.

Benefits of Negotiating Tooling Costs:

• Cost Savings: Negotiating tooling costs can result in significant savings, especially for large orders.
• Stronger Relationship: Negotiating with the manufacturer can help build a stronger relationship, leading to better terms and service in the future.
• Flexibility: By negotiating tooling costs, you may be able to secure more favorable terms, such as faster turnaround times or additional services.

7. Using PCB Prototyping Services

If you’re reordering PCBs for prototyping or small-scale production, consider using PCB prototyping services. These services are designed for low-volume production and often have lower tooling costs compared to traditional PCB manufacturing.

What Are PCB Prototyping Services?

PCB prototyping services specialize in producing small quantities of PCBs quickly and cost-effectively. These services are ideal for prototyping, testing, and small-scale production.

Steps to Reorder Using PCB Prototyping Services:

1. Choose a Prototyping Service: Research and select a PCB prototyping service that meets your needs. Look for services that offer low tooling costs and fast turnaround times.
2. Provide Your Design Files: Send your PCB design files to the prototyping service. Be sure to include all necessary files, such as Gerber files and drill data.
3. Place Your Order: Once the prototyping service has your files, place your order. Confirm that there are no additional tooling costs for reorders.

Benefits of Using PCB Prototyping Services:

• Lower Tooling Costs: PCB prototyping services often have lower tooling costs compared to traditional manufacturers, making them ideal for small-scale production.
• Fast Turnaround: Prototyping services are designed for quick turnaround times, allowing you to receive your PCBs faster.
• Flexibility: Prototyping services are often more flexible than traditional manufacturers, allowing you to make changes to your design without incurring additional costs.

8. Using Open-Source PCB Designs

If you’re working on an open-source project or are willing to use an open-source PCB design, you may be able to reorder PCBs without incurring tooling costs. Open-source PCB designs are often available for free and can be used by anyone, making them an excellent option for reorders.

What Are Open-Source PCB Designs?

Open-source PCB designs are designs that are freely available for anyone to use, modify, and distribute. These designs are often created by the open-source community and are available on platforms like GitHub, KiCad, and Eagle.

Steps to Reorder Using Open-Source PCB Designs:

1. Find an Open-Source Design: Search for an open-source PCB design that meets your needs. Be sure to check the license to ensure that you are allowed to use the design for your project.
2. Download the Design Files: Once you’ve found a suitable design, download the design files. These files should include Gerber files, drill data, and any other necessary files.
3. Send the Files to the Manufacturer: Send the design files to the manufacturer and confirm that there are no additional tooling costs for reorders.

Benefits of Using Open-Source PCB Designs:

• No Tooling Costs: Since the design is open-source, you can reorder the PCB without incurring additional tooling costs.
• Community Support: Open-source designs often come with community support, allowing you to get help and advice from other users.
• Customization: Open-source designs can be customized to meet your specific needs, giving you more flexibility in your project.

9. Using PCB Design Software with Built-In Manufacturing Features

Some PCB design software packages come with built-in manufacturing features that can help you reorder PCBs without incurring additional tooling costs. These features allow you to generate the necessary files and communicate directly with manufacturers, streamlining the reordering process.

What Are Built-In Manufacturing Features?

Built-in manufacturing features in PCB design software allow you to generate Gerber files, drill files, and other necessary files directly from your design. Some software packages also offer integration with PCB manufacturers, allowing you to place orders directly from the software.

Steps to Reorder Using PCB Design Software with Built-In Manufacturing Features:

1. Choose the Right Software: Select a PCB design software package that offers built-in manufacturing features. Some popular options include Altium Designer, KiCad, and Eagle.
2. Generate the Necessary Files: Use the software to generate the necessary files for your PCB design, including Gerber files, drill data, and any other required files.
3. Place Your Order: If the software offers integration with PCB manufacturers, use this feature to place your order directly from the software. If not, send the generated files to the manufacturer and confirm that there are no additional tooling costs for reorders.

Benefits of Using PCB Design Software with Built-In Manufacturing Features:

• Streamlined Process: Built-in manufacturing features streamline the reordering process, making it easier to generate the necessary files and place orders.
• Reduced Errors: By generating files directly from your design, you can reduce the risk of errors and ensure that the manufacturer receives accurate files.
• Cost Savings: Some software packages offer discounts or special deals with partnered manufacturers, helping you save on tooling costs.

10. Using PCB Assembly Services with No-Tooling-Cost Policies

If you’re reordering assembled PCBs, consider using PCB assembly services that offer no-tooling-cost policies. These services specialize in assembling PCBs and often have lower tooling costs compared to traditional manufacturers.

What Are PCB Assembly Services?

PCB assembly services specialize in assembling PCBs, including placing components, soldering, and testing. These services are ideal for reordering assembled PCBs, as they can handle the entire assembly process for you.

Steps to Reorder Using PCB Assembly Services with No-Tooling-Cost Policies:

1. Choose an Assembly Service: Research and select a PCB assembly service that offers no-tooling-cost policies for reorders. Look for services that specialize in small-scale production and prototyping.
2. Provide Your Design Files: Send your PCB design files to the assembly service. Be sure to include all necessary files, such as Gerber files, bill of materials (BOM), and assembly drawings.
3. Place Your Order: Once the assembly service has your files, place your order. Confirm that there are no additional tooling costs for reorders.

Benefits of Using PCB Assembly Services with No-Tooling-Cost Policies:

• Lower Tooling Costs: PCB assembly services often have lower tooling costs compared to traditional manufacturers, making them ideal for reordering assembled PCBs.
• Convenience: By using an assembly service, you can outsource the entire assembly process, saving you time and effort.
• Consistency: Assembly services ensure consistent quality across all units, reducing the risk of errors and defects.

Conclusion

Reordering your previous PCBs or assembled PCBs without incurring tooling costs is entirely possible with the right approach. By reordering from the same manufacturer, using Gerber files, leveraging no-tooling-cost policies, and exploring other cost-saving strategies, you can significantly reduce your expenses while maintaining the quality of your PCBs. Whether you’re a hobbyist, an engineer, or a business owner, these methods can help you save money and streamline your PCB reordering process. Remember to communicate clearly with your manufacturer, verify your design files, and explore all available options to ensure a smooth and cost-effective reordering experience.