How to Get a Quickturn PCB Prototype ？

Table of Contents

The Benefits of Quickturn PCB Prototypes

Getting a quickturn printed circuit board (PCB) prototype manufactured can provide numerous benefits during the electronics design process. Some key advantages include:

Faster design iteration – Rather than waiting weeks or months for a standard PCB fabrication, a quickturn prototype can be produced in just a few days. This allows you to test your design, make modifications, and order another prototype in less time.
Early validation – With a physical PCB prototype in hand early in the development cycle, you can validate the design performance, fit and function. This reduces risk and prevents costly mistakes later on.
Accelerate time-to-market – Getting prototypes rapidly shortens the overall development timeline and allows you to bring finished products to market faster.
Lower costs – Although quickturn fabrication has higher per-unit costs, it reduces costs overall by preventing late stage re-designs.

When to Order a Quickturn Prototype

Here are some common situations when it makes sense to get a quickturn PCB prototype:

Testing a new circuit design idea
Verifying layout before starting production
Confirming design changes or revisions
Assembling prototypes for demos and pilots
Short runs needed faster than standard turn times
Replacing a faulty prototype board quickly
Field testing design performance and reliability

For complex or high value designs, the benefits of rapid prototyping usually outweigh the costs.

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Choosing a Quickturn PCB Manufacturer

Selecting the right quickturn PCB manufacturer is key to getting high quality prototypes delivered fast. Here are some important factors to consider:

Turn Time

Look for manufacturers that offer turn times of 5 days or less. Many have 2-3 day rush options.
Ask about lead times for your location and board complexity. Priority prototyping shops can sometimes deliver in just 24-48 hours.

Location

Use a manufacturer with a facility located near you to minimize shipping time and costs.
For best results, select a shop located in the same country or time zone.

Order Flexibility

Choose a company that allows ordering PCBs in small quantities, even single boards.
Seek instant quoting and ordering to avoid delays.
Make sure you can make fast design tweaks and do same day re-orders.

Quality & Reliability

Verify the company has expertise in quickturn and rigorous quality control.
Examine example boards to check quality of substrates, silkscreening, solder mask, etc.
Avoid shops with poor customer reviews and feedback.

Comparison of Major Quickturn PCB Manufacturers
Company	Turn Time	Locations	Min. Order	Quality Reputation
PCBWay	24 hours	China	1 board	Excellent
JLCPCB	24 hours	China	5 boards	Very Good
RAYMING PCB	48 hours	China	1 board	Good
OSH Park	3 days	USA	3 boards	Very Good
Epec	3 days	USA	No min.	Excellent
Advanced Circuits	4 days	USA	No min.	Excellent
Sierra Circuits	5 days	USA	No min.	Excellent
Hillman Curtis	5 days	USA	No min.	Very Good

Additional Services

Look for a manufacturer that can provide all-in-one services:

Assembly – Get boards with components soldered
Testing – Opt for full functional testing if needed
Parts sourcing – Get kitted parts for DIY assembly
Stencils – Order paste stencils for soldering SMD parts
Design review – Verify manufacturability before ordering
Special materials – e.g. RF materials, flex, HDI
Certifications – ITAR, AS9100, MIL-PRF, etc.

Preparing PCB Prototype Design Files

To ensure a quick and problem-free order, it’s important to prepare design files correctly. Here are some tips:

Choose the Right CAD Tool

Many PCB design tools are compatible with prototype shops, but the most popular options include:

Altium Designer
Cadence Allegro and OrCAD
Mentor Graphics Xpedition
Autodesk Eagle
KiCad (open source)

Avoid specialty or proprietary tools that manufacturers may not support.

Include All Necessary Details

Supply all required data in your manufacturing Gerber and drill files. Here are some essentials:

All copper layers (top, bottom, internal)
Silkscreen layer for component markings
Solder mask layer for insulating copper
Drill file for holes and vias
Netlist or bill of materials for assembly
Board outline for cutting the PCB
Any mechanical details – cutouts, slots, holes, etc.

Follow Design Rules and Guidelines

Adhere to your manufacturer’s design rules to avoid issues with:

Trace/space clearances
Minimum trace widths
Annular rings for vias and pads
Mask expansion rules
Copper thickness and finished plating

Their capabilities may exceed standard rules, so confirm before assuming limitations.

Include Test Points and other Design Aids

Add pad/via test points for probing with multimeter or oscilloscope
Include component markings on both sides of board
Put board ID text and polarity markers for easy assembly
If applicable, include jig/fixture holes or edges

These features make prototype debugging and testing much easier.

Design for Manufacturability

Avoid potential fabrication problems by designing for manufacturability:

Allow adequate clearance around board edges
Avoid traces between closely spaced pins
Keep high voltage and sensitive signals away from board edges
Use surface mount devices where possible vs. through-hole
Minimize board shapes with tight angles

Reviewing your design with the PCB manufacturer can catch issues early.

Save Gerber Files Correctly

Pay close attention when generating Gerber files to avoid common mistakes:

Ensure all layers are output in the correct order
Check that all copper features image properly
Set appropriate aperture sizes for traces and pads
Exclude all draft components, silkscreen, and dimensions
Confirm board outline is in the right layer

Having the PCB company double check your layers is recommended.

Transmit Files Securely

Upload your Gerber files directly to the manufacturer’s website if possible
Compress files to ZIP or RAR if needed to reduce size
Avoid using consumer file sharing sites like Dropbox or Google Drive
For ITAR or other sensitive data, encrypt files and transmit securely

This protects your valuable intellectual property.

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Placing Orders with Your Prototype Manufacturer

Here are some tips for smoothly ordering once you’ve chosen a PCB manufacturer:

Get an Instant Online Quote

Use the company’s web quoting tool for upfront pricing
Enter all required details about size, layers, quantity, time, etc.
Check price both with and without assembly to compare
Request additional rush or expedited services if needed

Having a live quote avoids surprise costs when ordering.

Order Directly Online

Upload your design files and order directly on the website
Enter payment details, preferred shipping method, etc.
Double check the order for accuracy before submitting
Save or print a copy of the order acknowledgment

This creates a faster and more efficient process.

Provide All Required Information

Include all necessary Gerber files and documentation
Fully describe any special board requirements
Enter relevant notes for manufacturing in any comment fields
List an accurate count of PCB quantities needed
Specify preferred shipping carrier and account number

Missing information can delay orders and prototyping time.

Order Multiple Copies

Start with at least 2-3 copies of initial board designs
Order 5+ copies once design is closer to completion
Get a few extra boards for possible reworking or damage
Require only 1-2 boards for simple design validation

This provides boards for testing plus potential backup stock.

Confirm Order Details

Verify all order specifics like quantity, size, layers, etc.
Re-check the shipping address is correct
Ensure payment method is valid before submitting
Call manufacturer after ordering if any uncertainties

Getting order details right the first time prevents errors.

Receiving and Testing Your Prototype Boards

Once your quickturn PCB order ships, be sure to thoroughly inspect and test the boards on arrival:

Carefully Examine Boards

Review PCBs in detail under bright lighting
Check for any signs of physical damage in handling/shipping
Verify boards match your design files and Gerbers perfectly
Inspect PCB quality – mask alignment, text print, copper, etc.
Look for any evidence of manufacturing defects or flaws

Catching defects early prevents wasting time assembling bad boards.

Functionally Test Prototypes

Perform basic power-on and smoke tests first
Verify key voltages, clocks, and power rails
Load firmware/software and test progressively deeper functionality
Run boundary tests on all major sub-systems and I/O
Check results of any built-in self-diagnostics

Make sure your prototype actually works as designed before moving forward.

Repair Any Issues

Fix minor physical flaws like masking drips with razor, alcohol, etc.
Repair damaged corner, slots, or drill holes with files if possible
If reasonably fixable, repair traces or vias with bodge wires
For deeper issues, contact manufacturer about replacement
Have spare boards handy in case damage is irreparable

DIY repairs can resolve some fabrication defects cost effectively.

Retain Boards with Known Issues

Keep but set aside any prototypes with unfixable flaws
Save these as samples for failure analysis or future reference
Don’t assemble or use these boards further if non-functional
Label clearly to prevent using bad boards inadvertently

These failed boards may provide clues if other issues emerge later.

Provide Feedback to Manufacturer

Contact PCB company with feedback on quality or issues
Send photos of any defects for their failure analysis
Suggest improvements on any process weaknesses identified
Provide positive feedback if boards meet or exceed expectations

Your constructive input helps them continuously improve.

Assembly, Testing and Iterating Your Prototype

Once you have prototype boards in hand, here are tips for rapid assembly, test and additional iterations:

Assemble Just a Few Boards Initially

Hand assemble first prototype board only until design validated
Then assemble small quantity of 2-5 boards for comprehensive testing
Outsource assembly for larger quantities or complex designs
Keep first board intact; use others for repairing or modifications

This incremental approach prevents wasting time and money.

Use Modular Design Techniques

Partition complex boards into smaller sub-assemblies
Design modules for easy assembly and configuration changes
Create test points between module boundaries
Standardize connectors and interfaces for module swapping

Modularity supports quickly assembling and altering prototypes.

Design for Rapid Assembly

Lay out boards for easy hand soldering of through hole components
Place test points and status LEDs conveniently along board edges
Group related circuits together into functions or modules
Clearly label components, connectors, jumpers, and switches

Well organized boards assemble faster and with fewer errors.

Verify Assembly Quality

Closely inspect solder joints under magnification
Reflow joints with insufficient solder
Check for missing, misaligned or reversed components
Verify polarized capacitors, diodes, ICs are correct
Shake boards gently to check for loose parts

Most prototype problems start with assembly defects.

Perform Incremental Testing

Power up gradually and test progressively from basic to complex
Start with DC voltages, grounds, power rails, fuses, etc.
Advance to clock inputs, reset circuits, oscillators, etc.
Exercise digital logic, state machines, interfaces bit by bit
Finish with full performance testing at speed, load, stress, etc.

Incremental testing quickly isolates any failures.

Modify and Iterate Faster

Wire in patch components and links with solder or clips
Swap ICs in sockets to test firmware or logic changes
Adjust analog values with potentiometers and trim pots
Use DIP switches or jumpers for digital logic modifications
Keep replacement components handy for quick substituion

Simple mods allow rapid design tweaks between prototype turns.

Tips for Faster Prototype Turnaround

Here are some additional techniques you can use to reduce the time required for prototype turns:

Order from Local Quickturn Shops

Use a manufacturer located in your own country or region
Avoid overseas shops when fastest turn time is critical
Pay extra for domestic 2-3 day priority service if needed
Pick up prototype orders locally to avoid shipping delays

Save days versus overseas manufacturing and shipping.

Supply Design Files Upfront

Send Gerber files to manufacturer in advance if possible
Get feedback on any manufacturability concerns before finalizing design
Have them do design rule checks ahead of time
Authorize order in advance so it starts immediately upon receipt of final files

Early file transfer reduces turn time.

Pay for Expedited Services

Take advantage of expedited turn options even if boards cost more
For ultra-fast turns, some shops stock common materials onsite
Pre-pay for the order to avoid any financial approval delays
If available, pay extra fees for weekend or overtime work

These accelerate prototyping when needed to meet deadlines.

Standby for Prompt Design Mods

Be prepared to turn revised designs fast when you receive prototypes
Keep designers on standby to make any critical modifications
Transmit file changes digitally to avoid physical shipping
Pre-authorize remakes so they can start immediately if needed

No delays between receiving, revising and re-ordering.

Provide Clear Communications

Provide accurate design requirements upfront
Clearly explain any special prototyping needs
Promptly respond to all manufacturer inquiries
Give explicit feedback on any problems requiring rework
Thank manufacturers for timely responses and efforts

Good communication reduces delays on both sides.

Conclusion

Quickturn prototyping can significantly accelerate electronics product development, while reducing project risks and costs. Choosing an experienced PCB manufacturer, carefully preparing your design files, ordering multiple copies, thoroughly testing the results, and iterating rapidly leads to the best results. With a well planned process, you can have high quality working prototypes in hand in less than a week. The ability to progress through multiple prototypes quickly let’s you perfect your design faster.

Frequently Asked Questions

Q: What is the main benefit of quickturn PCB prototyping?

A: The key advantage is the ability to quickly test new designs, make modifications, and re-test improvements in less time. Short turnaround times accelerate overall product development.

Q: What is a good turnaround time to look for?

A: For fast validation, look for manufacturers that can deliver prototype boards in 5 days or less. Two to three day turn times are ideal for urgent projects.

Q: How many prototype boards should I order initially?

A: Start with 2-3 boards first for basic validation. Order 5-10 once the design is closer to completion for comprehensive testing. Always get a few spares.

Q: Should I assemble prototypes myself or use the manufacturer?

A: For simple designs, hand assemble the first board yourself. For complex projects or higher quantities, use the manufacturer’s assembly services.

Q: What do I do if my prototype PCBs have defects?

A: Contact the manufacturer right away with feedback and photos of any significant issues. Keep flawed boards for failure analysis and re-order replacements promptly.