Introduction

Printed circuit boards (PCBs) are an essential component of electronic devices and products. For many companies, getting PCB prototypes manufactured quickly and with a fast turnaround time is critical during the design and development process. This allows engineers to test and iterate on their designs rapidly.

In this article, we will examine what fast turnaround PCBs are, why they are important, how to get boards fabricated rapidly, and some tips for ensuring quick manufacturing times.

What Are Fast Turnaround PCBs?

Fast turnaround PCBs refer to printed circuit boards that are manufactured and delivered with very short lead times, usually between 24 hours to around 5 days. This is much faster than typical PCB production times, which can range from 2-4 weeks for standard services.

Some key characteristics of fast turnaround PCB services:

• Extremely quick fabrication and assembly timelines, enabled by optimized manufacturing processes.
• Lead times ranging from 24 hours up to 5 days in most cases.
• Limited to prototyping and low volume production, not suitable for mass production runs.
• Cost is higher than standard services but important for accelerating development.
• Offered by PCB manufacturers that specialize in rapid services.

Fast turnaround is critical during the design and testing phases of product development to allow for quick iterations and modifications of the board as issues are found.

Reasons for Using Fast Turnaround PCBs

There are several key reasons why engineers and companies need fast turnaround PCB services:

• Faster product development – Quick turnaround allows multiple design iterations to be tested in parallel. This accelerates the overall development timeline.
• Early validation – Testing prototypes early with real printed circuit boards provides validation of the design much sooner.
• Meet tight deadlines – Fast turnaround allows projects with short timeframes to be completed on schedule.
• Quicker time-to-market – Getting functioning prototypes faster enables bringing the product to market quicker.
• Test new concepts – New ideas and technologies can be iterated on rapidly with quick board turns.
• Respond to changing requirements – Design changes can be incorporated and tested in days rather than weeks.

For these reasons, access to fast turnaround PCB fabrication is essential for many engineering teams today.

How to Get Fast Turnaround PCBs Manufactured

There are a few key steps to follow in order to get your PCBs manufactured with a fast turnaround time:

1. Choose a Manufacturer Specializing in Fast Turnaround

There are a number of PCB manufacturers that offer specialized services for fast turnaround boards. When choosing a supplier, look for:

• Lead times ranging from 24 hours to 5 days advertised
• Domestic manufacturing preferred for fastest speed
• Additional rush and expedited services
• Strong reviews and reputation for on-time delivery

Some of the leading fast turn PCB manufacturers include:

• PCBWay – 24-72 hour lead times
• JLCPCB – 24-48 hour lead times
• Elecrow – 48-72 hour fabrications
• Sierra Circuits – 24-120 hour times

2. Provide Complete Design Files

To avoid any delays, be sure to provide the board house with all the necessary design files they require to fabricate the boards. This usually includes:

• Gerber files for all layers
• Drill files
• Bill of materials
• Any special instructions

Check the manufacturing requirements and make sure everything they need is supplied with your order. Having to request additional files can delay your order.

3. Choose Expedited Shipping Options

When available, choose the fastest shipping methods the manufacturer offers to reduce the time in transit. This gets the boards delivered quicker once fabrication is complete.

Options like DHL Express, UPS Worldwide Expedited, FedEx Priority Overnight etc will get your boards to you the fastest. It will add to the cost but can shave off a day or more in some cases.

4. Follow Up and Check Progress Frequently

It’s a good idea to check in with your PCB manufacturer frequently to track the status of your order. Many will provide regular email or website updates on the production process.

This allows you to know if everything is on track or if any issues come up. Catching problems early improves the chances of avoiding delays.

Tips for Optimizing Fast PCB Turnaround Times

To help ensure your boards get fabricated as quickly as possible, here are some useful tips to follow:

Keep Design Simple

Complex, dense PCB designs take longer to manufacture. Simpler layouts without tiny traces or spacing can be produced much quicker. Stick to minimum trace/space rules and avoid complex land patterns when possible.

Avoid Tight Tolerances

Tight tolerances slow down processes like imaging and etching. Allow for larger tolerances on features like trace width and spacing. This gives more margin for error and faster fabrication.

Minimize Layer Count

Stacking up too many layers can lead to fabrication issues and yield problems, adding to lead time. Try to design with fewer layers when feasible – 2-layer boards are ideal for fast turnaround.

Provide Design Files Immediately

Any delays in getting your Gerber files, drill files, and BOM to the manufacturer will add time. Provide completed design files as soon as you place the order.

Order in Standard Sizes

Standard PCB sizes like 100mm x 100mm or 100mm x 150mm panels are easier to produce quickly than custom sizes. Stick to the manufacturer’s standard size options when possible.

Wait Until Design is Finalized

Avoid tweaking the design and requesting engineering changes once submitted, as this can significantly delay your order. Get the design in a manufacturable state before sending to fab.

Conclusion

Fast turnaround PCB prototyping enables testing and iterating on designs rapidly to accelerate development. By partnering with the right manufacturer, providing optimized design files, and following expedited processes, engineers can have boards fabricated and delivered in just 24-48 hours in many cases. This quick turnaround is critical for meeting tight project deadlines and getting products to market faster.

Frequently Asked Questions

Here are some common questions about fast turnaround PCBs:

What is the quickest PCB turnaround time available?

Some manufacturers can deliver in as fast as 24-48 hours from receiving order and complete design data. This is typically the fastest service available.

Does faster turnaround affect quality and reliability?

No, manufacturers use the same fabrication processes whether standard or fast turnaround. The only difference is prioritizing orders for faster throughput.

How many times can I iterate on the design with fast turnaround?

Most companies allow unlimited iterations. You pay for each board fabricated, allowing testing of as many revisions as needed.

What are the main factors affecting turnaround time?

The complexity of the design, number of layers, board size, shipping method, and how optimized the design files are provided all impact total turnaround time.

Is there a minimum order quantity for fast turn PCBs?

Most manufacturers require 5-10 board minimums for fast turn services. This allows setting up fabrication processes for such small quantities.