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KoreanPCB Cost Reduction: Saving on Base Materials
Why 70–80% of PCB manufacturing costs are defined in layout & design
(e.g. for FR-4 PCBs)
A large share of PCB manufacturing costs is already determined in the early design phase. That’s why it is essential for developers to understand the fundamentals of PCB production – only then can costly mistakes be avoided and economically efficient solutions achieved.
At the same time, purchasers play a key role: they must balance price and quality while also understanding how technical requirements impact lead times and overall costs. Close collaboration between developers, procurement, and suppliers is therefore crucial.
Base Material as a Key Cost Driver
The base material (also referred to as substrate) is the foundation of every PCB, onto which the conductive copper layers are applied. It defines the mechanical, electrical, and thermal properties of the board – and has a significant impact on manufacturing costs.
FR-4 – The Most Common PCB Material
FR-4 is the most widely used base material for PCBs. It consists of:
- Copper foil
- Fiberglass layers
- Epoxy resin
In simplified terms, these components each represent roughly a quarter of the total material cost – with production costs forming the remaining share.
Base material becomes a major cost factor when applications require higher frequencies (e.g. >2 GHz) or elevated operating temperatures (e.g. >70°C continuous operation).
Copper – A Central Cost Driver
Copper is the core conductive material in every PCB – and one of the most significant cost drivers.
Its price is traded globally and subject to fluctuations. During periods of high demand or limited supply, copper prices increase – directly impacting PCB costs.
In addition, copper thickness has a strong influence on production costs:
- Standard copper (e.g. 35 µm) is cost-efficient and widely used
- Heavy copper (e.g. 70 µm, 105 µm or more) requires specialized etching processes and longer production times
Copper also affects other manufacturing steps such as drilling, routing, and lamination – further influencing lead times and unit costs.
Size and Shape as Cost Factors
The size and geometry of a PCB also impact cost.
- Larger boards require more material and increase manufacturing costs
- Non-standard shapes (e.g. square or complex geometries) can lead to higher production effort and reduced efficiency
EVYTRA Recommendation
To optimize costs, consider the following:
- Monitor raw material markets and price developments
- Choose copper thickness as low as possible – and only as high as technically necessary
- Evaluate whether selective reinforcement (e.g. only on power layers) is sufficient
- Whenever possible, use standard FR-4 materials in accordance with IPC 4101 or 4102
- If you are looking for cost optimization potential or are unsure about material selection, involve an experienced partner early in the process.
Optimize Your PCB Costs
From material selection to manufacturing strategy – EVYTRA helps you identify efficiency potential at every stage.
Discover more cost-saving tips in our blog or get in touch with us directly to define your optimal PCB sourcing strategy.