SMT Assembly Cost 2025

SMT assembly cost typically ranges from $50 to $500+ per board, depending on complexity, component count, board size, and order quantity. Prototype quantities cost more per unit, while high-volume production significantly reduces per-board costs. For a simple board with 50 components in quantities of 100, expect $75-150 per board. Complex designs with 300+ components may cost $200-500 for prototypes but drop to $50-100 in volume production.

Higher order quantities significantly reduce per-unit SMT assembly cost through economies of scale. Setup costs (stencils, programming, tooling) are distributed across more units, and suppliers often offer volume discounts. A prototype order of 10 boards might cost $300 each, while 100 boards might be $100 each, and 1000 boards could be $50 each. The setup cost remains relatively fixed, so larger orders dramatically lower the per-unit price.

Key factors include: PCB complexity (layers, size, material), component count and types (standard vs. BGA/QFN), order quantity, turnaround time, single or double-sided assembly, testing requirements (AOI, X-ray, functional), stencil costs, special processes (conformal coating, potting), and component sourcing (turnkey vs. consigned). Design complexity, fine-pitch components, and specialized materials like Rogers boards also impact pricing significantly.

SMT stencil costs range from $50-$200 for basic framed stencils to $300-$800 for high-precision laser-cut stencils with fine apertures. Prototype stencils (frameless) are cheapest at $50-100, while production-grade framed stainless steel stencils cost $150-400. Nano-coated or step stencils for complex assemblies may reach $500-800. This is typically a one-time setup cost that's amortized across your order quantity.

Generally yes, SMT assembly is more cost-effective than through-hole assembly for medium to high volume production. SMT benefits from faster automated placement (up to 50,000 components/hour vs. manual through-hole insertion), smaller and cheaper components, higher board density, and reduced labor costs. However, setup costs may be higher for small prototype runs (1-25 units), where simple through-hole assembly could be more economical. For production runs over 100 units, SMT typically provides 30-60% cost savings.

Most SMT assembly services accept orders starting from 1-5 prototype boards, though costs per board will be higher due to setup fees. Some specialized prototype services have no minimum order quantity. Economic production typically starts around 50-100 units where setup costs become reasonable per unit. Optimal pricing usually begins at 500+ units. High-volume manufacturers may require minimum orders of 1000-5000 units but offer the lowest per-unit costs.

Reduce costs by: (1) increasing order quantity for economies of scale, (2) using standard, readily-available components, (3) optimizing board design for manufacturing (DFM), (4) accepting longer standard lead times instead of rush service, (5) minimizing special requirements like X-ray inspection or conformal coating, (6) using single-sided assembly when possible, (7) providing your own components (consigned), (8) batching multiple designs in one order, (9) avoiding exotic materials or fine-pitch components unless necessary, and (10) establishing long-term relationships with assembly partners for better rates.

Typical quotes include: component placement fees (per component or per board), stencil fabrication, solder paste application, reflow soldering, basic visual inspection, and simple electrical testing. Some quotes bundle these as a per-board price. Additional services often quoted separately include: PCB fabrication, component sourcing and procurement, AOI inspection, X-ray inspection for BGAs, functional testing, programming services, conformal coating, and packaging. Always clarify what's included to compare quotes accurately between different assembly houses.

Standard SMT assembly typically takes 5-10 business days after receiving components and bare PCBs. This includes setup, assembly, inspection, and testing. Prototypes with expedited service can be completed in 24-72 hours at premium pricing (50-200% higher costs). Complex boards with extensive testing may require 10-15 days. Turnkey services where the assembler sources components add 2-4 weeks for procurement. Lead time directly affects cost—longer standard lead times offer the best pricing.

Most SMT assembly services offer three options: (1) Turnkey - they source all components (most convenient but typically 10-20% markup on parts), (2) Consigned - you provide all components (lowest cost, maximum control), or (3) Partial turnkey - mix of both. Turnkey is ideal for prototypes and when you want convenience. Consigned works well when you have preferred suppliers or negotiated component prices. Consider lead times, minimum order quantities, and your expertise in component sourcing when choosing.