PCB Prototyping Methods: 5 Favorites

Introduction

Printed circuit boards need to go through a design and development process, part of which is generating a prototype for testing and debugging which will allow for any issues to be fed back into the design loop to improve the PCB until it becomes production ready.

There are 5 popular PCB prototyping methods that we will explore here, looking at the methodology, why it would be used along with the benefits and any drawbacks of each method.

Why do we prototype PCBs as early as possible?

At Sofeast, we do PCB prototyping as early as possible in the new product development (NPD) process for a few reasons.

First, it allows our engineers to test and verify circuit designs before moving on to more expensive and time-consuming stages of the NPD process, such as PCB fabrication and assembly. This can help to identify and fix any potential problems early on, saving time and money in the long run.

Second, prototyping PCBs allows our engineers to get your valuable feedback early on in the design and development process. This feedback can be used to improve the product design before it is finalized.

Examples of why early PCB prototyping during new product development is beneficial

Here are some specific examples of how prototyping PCBs early in the NPD process can be beneficial and how it will help you:

• Identify and fix design errors: Prototyping PCBs can help you identify and fix design errors, such as incorrect component placement or routing errors. These errors can be difficult and expensive to fix after the PCB has been fabricated.
• Test and verify circuit functionality: PCB Prototyping allows our engineers to test and verify the functionality of your product circuit design. This can help to ensure that the circuit will work as expected in real-world conditions.

The different types of PCB prototyping methods

There are 5 popular PCB prototyping methods that we see being used time and time again. Let’s go through them here:

Hand Soldering

What is the process?

Hand soldering is a manual process of joining electrical components to a printed circuit board (PCB) using a soldering iron and solder. The soldering iron is heated to a temperature that melts the solder, which is then applied to the joint between the component and the PCB. As the solder cools and solidifies, it forms a strong electrical connection.

Why is it used?

Hand soldering is the most common method for PCB prototype development because it is relatively inexpensive and flexible. It allows for quick changes to be made to the design and is well-suited for small-scale production.

What are the benefits of using it?

• Flexibility: Hand soldering allows for a great deal of flexibility in the prototyping process. Components can be placed and soldered in any order, and changes can be made easily.
• Cost: It is a relatively inexpensive prototyping method, especially for small quantities.
• Quality: With proper training and experience, hand soldering can produce high-quality results.

What are its drawbacks or limitations?

• Skill: Requires a skilled technician to achieve good results. It can be difficult to achieve accurate and good-quality solder joints, and it takes practice to develop the required skills.
• Speed: This is a relatively slow process, especially for complex PCBs.
• Scalability: Not well-suited for large-scale production.

Breadboard Prototype

What is the process?

Breadboarding allows components to be connected without soldering, making it a quick and easy way to prototype circuits. Components can be added and removed without damaging them, enabling rapid testing and verification, experimentation, and debugging.

Why is it used?

Breadboarding is used for PCB prototype development because it is a quick and easy way to test and debug circuit designs without the need to manufacture any kind of PCB. It is also a relatively inexpensive prototyping method, making it ideal for small-scale projects.

What are the benefits of using it?

• Quick and easy: This is a very quick and easy way to prototype circuits. Components can be added and removed without soldering, making it easy to experiment with different designs.
• Reusable: Breadboards are reusable, so they can be used for multiple projects.
• Inexpensive: These are relatively inexpensive, making them ideal for concept verification and initial testing of a circuit.

What are its drawbacks or limitations?

• Not suitable for complex circuits: Breadboarding is not well-suited for prototyping complex circuits, as the wires and jumper cables can become cluttered and difficult to manage.
• Not suitable for permanent circuits: Breadboarded circuits are not meant to be permanent. The connections can be unreliable, and the circuit may not be able to handle high voltages or currents.

Perfboard or Veroboard

What is the process?

Perfboard and Veroboard are prototyping boards with a grid of pre-drilled holes and copper traces. Components can be soldered onto these boards to create a semi-permanent prototype. Perfboard is a single-layer board, while Veroboard has two layers of copper traces connected by plated-through holes.

Why is it used?

Perfboard and Veroboard are used for PCB prototype development because they are a versatile and cost-effective way to create semi-permanent prototypes which is useful for testing and debugging circuits before soldering them onto a PCB. This is because the components can be easily removed and replaced on perfboard and veroboard.

What are the benefits of using it?

• Versatile: Both can be used to prototype a wide variety of circuit designs.
• Cost-effective: These boards are relatively inexpensive, making them ideal for small-scale projects.
• Semi-permanent: Prototypes can be made to be semi-permanent, which is useful for testing and debugging circuits before soldering them onto a PCB.

What are the drawbacks or limitations?

• Not suitable for complex circuits: They are not well-suited for prototyping complex circuits, as the wiring can become cluttered and difficult to manage.
• Requires soldering: Perfboard and Veroboard prototypes require soldering, this is where mistakes and poor-quality solder joints can introduce errors.

Prototyping Platforms (Arduino, Raspberry Pi, etc.)

What is the process?

The Arduino, for example, is a versatile prototyping platform that is powered by a simple microcontroller. It is easy to use and has a wide range of features that make it ideal for testing and debugging PCB circuits at the start of any project.

One of the key features of the Arduino is its support for hardware add-on boards called shields. Shields allow users to easily add new functionality to their projects, such as adding sensors, actuators, or communication modules. The Arduino is also very energy-efficient, making it ideal for battery-powered applications.

Why is it used?

Prototyping platforms are used for PCB prototype development because they are a fast and easy way to test and debug circuit designs. They are also a good way to learn about specific ICs and their functionality without having to design and fabricate a custom PCB.

What are the benefits of using it?

• Fast and easy: They are very fast and easy to use. There is no need to learn about PCB design or fabrication, and components can be plugged into the board and programmed without soldering.
• Versatile: Prototyping platforms can be used to prototype a wide variety of electronic projects, from simple circuits to complex devices.

What are the drawbacks or limitations?

• Not suitable for high-performance applications: With limitations on what can be achieved, they are not as efficient as custom-designed PCBs.
• Limited functionality: Include a limited set of features and functionality, which may not be suitable for all projects.

Wire Wrapping

What is the process?

Wire wrapping is a prototyping method that involves wrapping thin, insulated wires around posts or terminals on a prototyping board. The wire is wrapped tightly around the post, creating a strong and reliable connection. Wire wrapping is a quick and easy way to prototype circuits, as it does not require soldering.

Why is it used?

Wire wrapping is used for PCB prototype development because it is a quick and easy way to test and debug circuit designs. It is also a good way to make quick changes and adjustments to the circuit without having to desolder and resolder components.

What are the benefits of using it?

• Quick and easy: This is a very quick and easy way to prototype circuits. There is no need to learn about soldering, and components can be added and removed without damaging them.
• Flexible: Allows for quick changes and adjustments to the circuit. Wires can be easily added, removed, and rearranged.
• Reliable: Connections are very strong and reliable. They can withstand high temperatures and vibrations.

What are the drawbacks or limitations?

• Not suitable for complex circuits: This is not well-suited for prototyping complex circuits, as the wires can become cluttered and difficult to manage.
• Not suitable for high-volume production: Not a suitable method for high-volume production, as it is time-consuming and labor-intensive.

Conclusion on the importance of PCB prototyping as early as possible

As we have stated, prototyping PCBs as early as possible in the product development process is essential for ensuring a high-quality product that meets the needs of the product requirement. It allows engineers to test and verify circuit designs, get feedback from stakeholders, and identify and fix any potential problems before they become more expensive and time-consuming to fix later on.

At Sofeast, we are familiar with and use all of the PCB prototyping methods discussed in this article, including:

• Breadboarding
• Perfboard/Veroboard
• Wire wrapping
• Prototyping platforms

We can help you to choose the right prototyping method for your project and to create high-quality prototypes that will help you to bring your product to market quickly and efficiently.

Contact Sofeast today to learn more about our product development process and prototyping services.

P.S.

Sofeast has developed and worked on hundreds, if not thousands, of PCB designs, and during that time we have gained a lot of expertise which we share in some of our blog posts. You can read about the 40+ improvements that can be made through DFM for PCBAs here.

On our resources page, we have a video series on PCBs that you may find useful. You can see the content here.

Also, regarding your supplier, who to choose? CM + PCBA Factory vs. EMS Supplier in Shenzhen, China? Read about your options here.