EMS Cost Calculation Software with Digital Twin and True Costing

Frequently asked questions

How is manufacturing cost calculated from ODB++ or Gerber data?

PCBoffer reads the fabrication data directly: layer stack, copper weight, dielectric build-up, drill and via geometry including laser vias, routing and panelization. From that geometry it derives the process steps a board actually needs, and prices them against the work centers of your own plant. Nothing is typed in by hand that the CAD data already states.

What are NRE costs in PCB assembly?

Non-recurring engineering costs: the one-off costs of preparing a product for production rather than the per-piece cost: stencil, programming and setup of the placement lines, feeder setup, first-article inspection, test fixtures and process documentation. They dominate the price of a small batch and disappear into the noise on a large one, which is why they have to be shown separately per lot size instead of being averaged into a unit price.

How do I get assembly cost from a pick-and-place file instead of a flat surcharge per component?

Placement time is derived per component from the pick-and-place file, and selective soldering time from where the joints sit on the assembly. Wave and reflow times come from the conveyor and work-center model. All of it is parameterised with the machine park you actually own, not with generic industry averages, so a fine-pitch part on a slow line and a passive on a fast one no longer cost the same.

Can the cost model be calibrated against our own plant?

Yes. On-site calibration against the real plant is available with guaranteed accuracy. Beyond that, machine data flowing back from the shop floor corrects the model continuously, so the next calculation is based on what the plant really achieved rather than on assumptions that drift.

Does PCBoffer optimise PCB panelisation as well?

Yes, for the case that actually comes up in an EMS shop: an assembly is too small to run on the line on its own, so it is combined into a production panel. PCBoffer works through the possible arrangements and selects first by the number of runs, because printing, oven and handling are paid per run. On a reference board this makes the same order 26.4 % cheaper, purely through the choice of panel. How large the panel may become is calculated rather than configured: 0.5 mm of sag is allowed, because beyond that the nozzle misses the pad and the stencil no longer seals, and the copper counts towards the stiffness. Separating the panel itself, scoring or routing, is done by the PCB fabricator and is therefore not part of this calculation.Work out your own panel: the free panelisation calculator

What happens when a figure is not reliable?

It is flagged rather than used silently. For every value, the costing carries where it came from, what it affects and what PCBoffer suggests instead. Your work preparation corrects it by hand, decides on the suggestion, and only after that review does the quote go to the customer. For a part substitution this is an explicit approval step: the system proposes and gives its reasoning, a person approves or rejects. Every explanation also carries who it is meant for: markup logic, line capacity and machine and profile names stay in house, while the customer-facing explanations may travel with the quote. That is the guiding principle of the platform: automate where possible, keep every figure explainable, and let people decide where they are needed.