The electronics manufacturing industry is full of assumptions. Some are based on outdated information, while others have become accepted as fact despite not always reflecting the reality of modern manufacturing.
At Active-PCB Solutions, we regularly encounter misconceptions about PCB assembly, testing, inspection and manufacturing costs. While every project is different, understanding the facts behind these common myths can help businesses make more informed decisions when selecting a manufacturing partner.
Myth 1: UK Electronics Manufacturing Is Always More Expensive
One of the most common assumptions is that manufacturing overseas will always be the lowest-cost option and, while unit pricing can sometimes be lower, the true cost of a project often extends far beyond the PCB assembly price shown on a quotation.
Shipping costs, import duties, longer lead times, communication delays and supply chain risk can all introduce hidden costs that are not immediately visible during the procurement process.
For many organisations, working with a UK manufacturing partner provides greater flexibility, faster response times and reduced risk, particularly during prototyping, new product introduction (NPI) and low-to-medium volume production.
The lowest quote is not always the lowest overall cost. Read our blog post for more information.
Myth 2: Conformal Coating Is Only For Military And Aerospace Products
Conformal coating is often associated with defence, aerospace and other high-reliability sectors, leading many people to assume it has limited application elsewhere, but in reality, conformal coating can provide significant benefits across a wide range of industries.
Electronics exposed to moisture, condensation, dust, chemicals, vibration or temperature fluctuations can all benefit from the additional protection conformal coating provides.
Applications can include industrial automation equipment, transportation systems, energy infrastructure, outdoor electronics and many other products operating in challenging environments.
Whether conformal coating is beneficial isn’t just a question whether a product is military grade, it’s whether the operating environment justifies the additional protection.
Myth 3: Inspection Only Happens At The End Of Production
Quality control is often viewed as a final-stage activity carried out once a PCB assembly has been completed, however modern electronics manufacturing takes a very different approach.
Inspection and verification are integrated throughout the manufacturing process, helping to identify issues as early as possible.
Depending on the product and process requirements, this may include automated optical inspection (AOI), X-ray inspection, electrical testing and skilled manual inspection.
Identifying potential issues earlier helps reduce rework, improve efficiency and maintain consistent product quality.
Quality is not something that gets added at the end; it needs to be built into the manufacturing process from the start.
Myth 4: Lead time is only determined by manufacturing
Manufacturing is just one part of the overall timeline.
Material availability, PCB fabrication, engineering queries, customer approvals and logistics can all influence when a product is ready to ship.
Even the most efficient production line can’t build assemblies if critical components haven’t arrived or approvals are still outstanding.
Reducing lead times isn’t just about manufacturing faster – it’s about managing the entire process effectively from start to finish.
Myth 5: Any PCB Assembler Can Build Any Product
While Electronics Manufacturing Services companies may appear similar on the surface, they don’t all offer the same capabilities.
Different manufacturers have different equipment, certifications, processes and areas of expertise. Some specialise in high-volume production, while others focus on complex, high-mix or high-reliability assemblies.
The quality systems, testing capabilities, engineering support and account management structure behind a manufacturer can have a significant impact on project outcomes.
Selecting a manufacturing partner should involve much more than comparing prices alone, and conducting a site visit is usually a vital step in the decision.
Looking Beyond The Myths
Electronics manufacturing is a complex process, and many commonly held assumptions do not tell the whole story.
Whether evaluating manufacturing costs, considering conformal coating, planning testing strategies or selecting a PCB assembly partner, taking the time to understand the wider picture can help reduce risk and improve long-term project success.
If you would like to discuss your next PCB assembly project, the team at Active-PCB Solutions would be happy to help.
