Overview of the US PCB manufacturing industry

The United States was a pioneer in the development of PCBs and related technologies. The US PCB industry took off in the 1950s and 1960s to support the growing electronics and defense sectors. PCB manufacturing in the USA reached its peak in the 1980s before increasing amounts of production started to shift overseas in the 1990s and 2000s, particularly to Asia, to take advantage of lower labor costs.

However, the US still retains a robust PCB manufacturing base today, especially for high-performance, quick-turn, and prototype work. There are over 200 pcb fabricators in the USA, ranging from small shops to large corporations. In 2020, the US produced around $4 billion worth of PCBs, making it the 2nd largest PCB manufacturing country outside of Asia.

Advantages of US PCB manufacturing

There are several key advantages and benefits to manufacturing PCBs in the United States:

• Proximity to US customers enabling fast delivery times
• Ability to provide high mix, low to medium volume production
• Specialization in complex PCB technologies (HDI, rigid-flex, etc.)
• Strict quality control and reliability standards (IPC class 2 and 3)
• Protection of intellectual property (IP)
• Avoidance of tariffs and trade restrictions
• Ability to meet made-in-USA requirements

For many US electronics companies, the benefits of domestic sourcing for PCBs often outweigh the higher production costs compared to overseas. The ability to work closely with a US-based PCB supplier and have fast turnaround times is very valuable, especially for prototypes, quick-turn production, and sensitive projects.

PCB technologies and capabilities in the USA

US PCB shops fabricate a wide range of PCB types and have extensive capabilities in terms of materials, layer counts, minimum feature sizes, surface finishes, and more. Many US manufacturers specialize in complex PCB technologies such as:

• HDI (High Density Interconnect): PCBs with a high wiring density featuring small vias, fine lines/spaces, and high layer counts. Used for compact electronics.

• Rigid-Flex: PCBs that combine rigid and flexible substrates, allowing the board to be bent or folded. Used in wearables, portable devices, and tight spaces.

• RF/Microwave: PCBs engineered for high frequency signals, using low-loss dielectric materials and controlled impedances. Used in telecommunications, radar, and wireless equipment.

• Extreme Environments: PCBs designed to withstand harsh conditions such as high/low temperatures, shock, and vibration. Used in aerospace, military, oil & gas, and industrial applications.

Here is a table summarizing some key technical capabilities of US PCB manufacturers:

Capability	Typical Range in USA
Board Thickness	0.2 mm to 5.0 mm
Layer Count	1 to 40+ layers
Minimum Line Width	40 microns (1.6 mil)
Minimum Drill Size	100 microns (4 mil)
Laminate Materials	FR-4, high-Tg, Rogers, polyimide, flex
Schematic / Fabrication Formats	Gerber, ODB++, IPC-2511, IPC-254X

Of course, the exact capabilities vary by manufacturer. Some specialize in quickturn prototypes with a few layers, while others focus on complex high layer count boards in high volumes. Materials and surface finishes may be optimized for different applications as well. But overall, the depth and range of PCB technologies available in the US market is quite extensive.

Major US PCB manufacturers

Some of the leading PCB manufacturers based in the USA include:

TTM Technologies

• Location: Headquartered in California with multiple US facilities
• Capabilities: One of the largest US-based PCB fabricators. Offers HDI, rigid-flex, RF/microwave, and advanced technologies. Serves aerospace, defense, automotive, medical, industrial, and commercial markets.

Summit Interconnect

• Location: Based in California with several US plants
• Capabilities: Specializes in complex PCBs including HDI, rigid-flex, and RF/microwave. Serves military, defense, aerospace, and medical industries. Offers quick-turn prototypes to volume production.

Streamline Circuits

• Location: Based in California
• Capabilities: Specializes in quickturn prototypes and low-volume production. Offers 24-hour and 48-hour turns. Serves entrepreneurs, engineers, and electronics companies across many industries.

Calumet Electronics

• Location: Based in Michigan
• Capabilities: Focuses on high-performance PCBs for industrial and defense applications. Specializes in aerospace, power electronics, and RF/microwave boards. AS9100D and NADCAP certified.

Gorilla Circuits

• Location: Headquartered in California
• Capabilities: Provides quick-turn pcb prototypes and low-volume production. Specializes in 1-12 layer boards. Serves robotics, IoT, consumer electronics, and other industries.

Royal Circuit Solutions

• Location: Based in California
• Capabilities: Offers quick-turn prototypes to mid-volume production. Specializes in HDI, rigid-flex, and advanced PCBs. Serves aerospace, defense, medical, and commercial markets.

How to choose a US PCB manufacturer

With so many US PCB suppliers to choose from, how do you find the right one for your needs? Here are some key factors to consider:

Technical capabilities

Make sure the manufacturer can handle the types of PCBs you need in terms of layers, materials, sizes, surface finishes, and other requirements. Review their capabilities and request a DFM (design for manufacturability) check of your design files.

Industry focus

Consider whether the PCB fabricator has experience serving your industry and can meet relevant quality standards and certifications, such as ISO 9001, AS9100, ITAR, or NADCAP. Aerospace and defense projects may have additional requirements.

Production volume and lead time

Determine what type of volumes you need, from prototypes to mass production. Check the supplier’s capacity, available lead times, and whether they specialize in quick turns or higher volumes. Get production quotes based on your needs.

Domestic and offshore partners

Even if a PCB fabricator is based in the USA, they may have offshore manufacturing partners to provide additional capacity or lower pricing for certain projects. Check on their supply chain and whether they can provide a mix of domestic and offshore production.

Quality and service

Evaluate the supplier’s track record for quality, on-time delivery, and customer service. Ask for references, review online information and get a feel for their responsiveness and customer focus during your engagement with them.

By carefully evaluating potential PCB suppliers against your technical and business needs, you can find the right US manufacturing partner for your projects. Many US fabricators are well-equipped to provide high-quality PCBs with fast turnaround times.

FAQ

Are PCBs made in USA more expensive than overseas?

In general, PCBs manufactured in the USA do cost more than boards fabricated in Asia, often 30-50% higher or more depending on the project. US labor and overhead costs are higher. However, for many US customers, the benefits of using a domestic pcb supplier make the higher costs worthwhile, especially for low-volume, quick-turn, and high-complexity projects. The overall value is compelling when considering turnaround time, ease of doing business, IP security, and quality.

What are the typical lead times for US-made PCBs?

Lead times from US PCB manufacturers can range from 24 hours to 3 weeks or more. Many US PCB shops specialize in quick-turn production, with expedited options for 1-day, 2-day, and 5-day turns. Standard lead times are more often in the 1-2 week range. The exact lead time depends on the complexity of the design and the manufacturer’s workload. This is still significantly faster than the 3-6 week lead times often quoted from overseas suppliers.

How do I know if a PCB shop can make my design?

The best way to determine if a PCB fabricator can handle your design is to send them your design files for a manufacturability review. Most US PCB shops offer free DFM (design for manufacturability) checks where they analyze your design data and provide feedback on any issues or suggested changes. They will then confirm whether they can build your boards to your specifications. It’s a good idea to involve your PCB supplier early in the design process to avoid any problems down the line.

Can I get UL-listed PCBs from US shops?

Yes, there are a number of US PCB manufacturers who can fabricate UL-listed PCBs. Several US shops are UL-authorized fabricators who have had their processes and materials approved by Underwriters Laboratories (UL). They can provide UL-marked bare boards which saves you time and effort in getting your end product certified. Check with individual suppliers on their UL authorization and the specific UL standards they can certify to.

What are AS9100 and NADCAP?

AS9100 is a standardized quality management system for the aerospace industry. It is based on the ISO 9001 quality standard with additional requirements specific to aviation, space, and defense. Many US PCB shops serving the aerospace and defense industries are AS9100 certified.

NADCAP (National Aerospace and Defense Contractors Accreditation Program) is a global program that certifies suppliers to aerospace industry standards. PCB shops with NADCAP accreditation have demonstrated their manufacturing processes meet strict requirements for quality and reliability. NADCAP is often required for defense and aerospace electronics projects.

Conclusion

In conclusion, there is a robust PCB manufacturing industry in the USA with a wide range of capabilities. US-based PCB fabricators offer a compelling mix of technical expertise, quality, reliability, and fast turnaround times. While costs are higher compared to overseas production, the benefits of using a domestic supplier make it an attractive option for many US electronics companies, especially for prototypes, quick turns, and high-complexity boards.

If you are considering PCB manufacturing in the USA, research potential suppliers and evaluate them based on your technical requirements and business needs. Many US PCB manufacturers offer a strong combination of advanced capabilities, certifications, and customer service to meet your needs.

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