How Does Panelization Optimize Circuit Board Assembly Efficiency?

Optimize Circuit Board Assembly Efficiency

You’ve spent time sketching out a perfect PCB design that meets your exact specifications, taking into account EMI/EMC and thermal considerations as well as ensuring it fits within the tight enclosure of your final product. However, when you go to place an order with your preferred fabrication house, they tell you that their production machinery can’t handle single boards larger than a 2.0 inch conveyor width. Fortunately, they’re willing to help you out by suggesting panelization instead.

As its name suggests, panelization optimizes circuit board assembly efficiency by reducing the amount of space each individual component takes up on the finished product. This allows for mass production of the same type of PCB with more efficient use of materials and lower manufacturing costs. It also reduces processing times, as each piece can be handled and shipped at the same time instead of one at a time.

But what makes a PCB ready for panelization? There are several factors to consider, including the layout of the components on the board and the shape of the board. For example, it’s important to allow for adequate clearance between copper traces and planes, as well as overhanging components, so that the board can be easily broken into individual pieces during depanelization. The design should also take into account the shape of the board’s edges, as it may be difficult for automated picking tools to grasp irregular shapes.

How Does Panelization Optimize Circuit Board Assembly Efficiency?

In addition, it’s crucial to have a plan for how each individual panel will be separated once the fabrication process is complete. PCBs can be broken apart by hand or using a machine, depending on the needs of your application. Ideally, your PCB will be designed to accommodate either method, so that it’s easy to depanelize and ready for assembly.

There are two main methods of PCB panelization to consider when creating a design: V-grooving and tabs with mousebites. The V-grooving method creates a V-shaped groove on the top and bottom of each individual PCB in an array, so that the boards can be snapped or broken apart by hand or machine without needing to remove any other components from the board. This is often the most cost-effective solution, especially for high-volume applications.

The second option, tab routing, works best for designs that can’t feasibly use the V-groove method, or for boards that require a higher level of separation for a particular application. This method creates perforation patterns on the sides of each array, with between three and five holes in each pattern. Individual panels can then be broken by hand or using a machine, and each panel is still held in place on the board with small breakout tabs that are easily removed. Tabs are typically made of a rigid material such as plastic, so they won’t break as easily as the copper traces and planes on the board. They also provide a strong connection between the individual boards, helping to prevent them from shifting or breaking during assembly and testing.