Why Outsourcing PCB Fabrication Online is Ideal for Makers

Outsourcing PCBs has gained significant traction, especially with the rapid growth of the global PCB market. Valued at USD 69.69 billion in 2023, the market is projected to expand to USD 113.49 billion by 2032, exhibiting a CAGR of 5.9%.

One of the driving factors behind this shift is the growing complexity of modern electronics, which demands highly precise and multi-layered PCBs—technology that small-scale makers and hobbyists cannot easily replicate. By outsourcing, even small developers gain access to professional-grade boards without the need for expensive equipment.

Today, outsourcing PCB fabrication to professional manufacturers online has become the go-to solution for many electronics creators and makers. But why has outsourcing become such a popular choice?

The DIY Approach

Hobbyists and makers have traditionally used methods like the toner transfer technique or photoresist etching for fabricating PCBs at home. And more recently, CNC milling machines have gained popularity among this group.

CNC offers a faster way to create prototypes by milling away copper from the PCB board without the need for messy chemicals. The advantage here is precision and speed. Once the design is set up, the process is repeatable and offers a quicker turnaround.

That said, these types of fabrication methods do come with limitations. They are ideal for quick prototyping but struggle with more complex designs, especially when it comes to high-density or multi-layer boards that are now common in modern electronics​.

For hobbyists, the DIY approach has a certain charm. It’s hands-on, and you learn a lot in the process. But for more creative and advanced projects, it’s easy to see how the limitations start piling up.

Online Outsourcing: A Modern Solution

Today, the electronics world has evolved, and so have the needs of makers and professionals alike. Many makers now outsource their PCB manufacturing instead of manually creating their boards.

Here’s how it typically works: once you’ve designed your PCB using software, like KiCAD or Fusion 360, you export the Gerber files (and sometimes other files like drill files) and send them directly to a PCB fabrication service.

Manufacturers like JLCPCB, PCBWay, and Seeed Studio offer easy-to-use online platforms where you upload your files, choose specifications (such as board thickness, number of layers, solder mask color, etc.), and place your order. These manufacturers are equipped with sophisticated machinery to handle everything from small prototype runs to large-scale production.

Why Outsourcing is the Smart Choice

Cost Efficiency

Making PCBs in-house might seem like a cost-saving measure at first, but the costs quickly add up—chemicals, copper boards, drills, equipment maintenance, and the possibility of having to redo boards due to mistakes.

When you outsource, you benefit from economies of scale. Many manufacturers offer incredibly affordable pricing, even for small prototype runs.

For instance, JLCPCB offers prototype PCBs starting at just $2 for five boards, far less than what you’d spend on materials alone for DIY fabrication.

Access to Advanced Technology

Outsourcing PCB gives you access to technologies and manufacturing techniques that you can’t replicate at home. For example, multi-layer PCBs, advanced surface finishes, and high-density interconnects (HDI) are only possible with professional equipment.

For example, if you’re working on a project that needs a 4-layer PCB to support its complex system, it would be impossible to fabricate such a complex design yourself.

Quality and Precision

Professional PCB manufacturers have strict quality control processes. Boards are inspected using automated optical inspection (AOI) and other advanced testing techniques, ensuring that every trace and pad is perfectly aligned. This is crucial for complex designs where precision is essential for functionality.

Scalability

One of the most significant advantages of outsourcing is scalability. Whether you need just five boards for a prototype or thousands for a production run, PCB manufacturers can scale the process effortlessly. This flexibility allows hobbyists and professionals alike to grow their projects without worrying about the limitations of in-house manufacturing.

The Role of PCB Software

Today’s PCB design software, like Altium Designer, KiCad, and Fusion 360, makes the process of outsourcing even smoother. These programs allow you to generate the necessary Gerber files and other manufacturing documents with ease.

Most PCB manufacturers have clear guidelines on how to export these files to ensure compatibility with their systems. Some manufacturers also offer an online Gerber viewer that allows customers to preview their files before submission, ensuring all design elements are correct. This step helps catch errors early, such as misaligned components or missing data, which can cause issues during production.

Limitations of PCB outsourcing

While outsourcing PCBs offers numerous benefits, it’s essential to recognize that it also comes with some limitations. These limitations might not be deal-breakers but are important to keep in mind, especially when planning your projects.

Communication and Lead Times

One of the most significant limitations of outsourcing, particularly when working with overseas manufacturers, is communication and lead times. While many PCB manufacturers have streamlined processes for receiving orders, there are times when miscommunications about design specifics can occur. If any design corrections or clarifications are needed after submission, the back-and-forth process can delay your project.

Additionally, even though many companies offer fast turnaround times, shipping and customs processing can introduce unexpected delays. If you’re working on a tight schedule, this can be a significant drawback compared to the immediacy of fabricating a PCB in-house.

Limited Control Over Manufacturing Process

When you outsource your PCB production, you hand over control of the manufacturing process to a third party. While most PCB manufacturers follow strict quality control protocols, you’re still relying on their processes to ensure your boards meet your standards. Mistakes can happen, and although most manufacturers will rectify any issues, the time required to remake and reship defective boards can lead to project delays.

Minimum Order Quantities and Pricing for Small Runs

Many PCB manufacturers offer low-cost prototypes, but there can still be limitations on order quantities. Some services have minimum order requirements that might not be ideal for hobbyists or students who only need one or two boards.

Additionally, while the price per board tends to drop with higher volumes, very small runs can still be more expensive on a per-unit basis.

For instance, if you only need a single board for a one-off project, the shipping cost and minimum quantity might not justify outsourcing, particularly if you’re working within a limited budget.

Prototype Testing and Iteration Delays

In-house PCB production allows for faster iterations when prototyping. If a design doesn’t work as intended, you can make changes on the spot and immediately fabricate a new board. When you outsource, every design change requires submitting new files, waiting for fabrication, and then waiting for shipping. This can slow down the iterative process of prototyping, where you may need to test multiple versions of a board before finalizing the design.

For makers or teams developing innovative products, these delays can lead to frustration, particularly when working with highly experimental designs. Speed and flexibility are often essential during the prototyping phase, and outsourcing can sometimes be a bottleneck in this regard.