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KoreanPanel Utilization: How It Impacts PCB Unit Cost
Why PCB unit cost is already determined by panel utilization in production
Panel utilization (also referred to as yield or utilization) describes how efficiently the area of a production panel is used for your printed circuit boards. The principle is simple: the more PCBs that fit onto a panel, the lower the unit cost.
Accounting for Panel Margins
However, not all of the panel area can be used. Every manufacturer requires a process-related margin for handling and fixation during production.
For more complex designs, additional space is needed for test coupons used in quality assurance. The width of these margins varies depending on the manufacturer and typically increases with the number of layers.
Each manufacturer defines a handling area within the panel that cannot be used for PCB placement. As a general rule: the higher the layer count, the wider the required margin.
While manufacturers aim to maximize utilization, full panel usage is not possible.
A good utilization rate might be around 77.8%, whereas a poor one could be closer to 52%.
In practical terms, this means:
With good utilization, you may get 3 PCBs for the same cost as 2 PCBs with poor utilization.
Jeder Hersteller definiert im Randbereich eines Produktionspanels einen Bereich, der für die Handhabung im Produktionsprozess benötigt wird. In der Regel gilt. Je höher die Anzahl der Lagen, desto breiter wird der Rand. Jeder Hersteller versucht zwar die optimale Auslastung zu erreichen. Allerdings kann nicht die gesamte Fläche genutzt werden. Eine gute Nutzenauslastung liegt bspw. bei 77,8 %. Eine schlechte Ausnutzung liegt bspw. bei 52 %. Bei einer guten Auslastung können bsp. 3 Leiterplatten dasselbe kosten, wie bei einer schlechten Auslastung 2 Leiterplatten.
Different PCB Manufacturing Approaches
There are numerous manufacturing processes in the market. Some manufacturers specialize in simple 1- or 2-layer PCBs, while others focus exclusively on high-complexity designs with 8 or more layers.
Additionally, different production equipment and process steps make direct comparisons difficult. Panel sizes are also manufacturer-specific:
- Some panels are optimized for specific processes or materials
- Others are optimized for volume production
As a result, panel sizes and utilization strategies vary significantly between manufacturers.
Typical Production Panels
Most raw materials are purchased in sizes of approximately 1200 × 1050 mm, which are then divided into multiple production panels.
Common panel dimensions vary depending on the manufacturer and production setup.
EVYTRA Recommendation:
Consider panel utilization early – it is a key factor for cost efficiency.
- Engage with your PCB manufacturer early in the design phase
- Understand how your PCB will be manufactured
- Plan your design to achieve optimal panel utilization
As a general guideline, we recommend avoiding excessively large board or panel sizes (>200–220 mm), as they can negatively impact cost efficiency.
Since PCB costs are largely driven by design decisions, it is worthwhile to estimate costs early in the development phase.
The most reliable way to determine the actual price remains a direct inquiry with your trusted supplier.
Plan Your PCB Cost-Efficiently
EVYTRA supports you in making the right decisions early in the development phase to achieve optimal panel utilization.
Get in touch with us and secure an efficient, cost-effective PCB sourcing strategy.