PCB Fabrication

PCB Fabrication China Printed Circuit Boards Manufacturer

Here at Zapon, we provide a full feature PCB service. With 10+ years’ experience in PCB manufacturing, we have handled hundreds of thousands of PCB projects, and covered almost all kinds of substrate material including Standard FR4, Aluminum, Rogers, etc.

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  PCB Assembly

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  Flex-Rigid PCB

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  Aluminum PCB

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  Flexible PCB

WHY CHOOSE ZAPON

• On Time Delivery

• Good Customer Services

• Over 80 Countries

As China printed circuit boards manufacturer, Zapon offer you expanded PCB capabilities and exclusive services. and also provide excellent customer service for each and every order.
We are professional Prototype and Production PCB manufacturer from China, dedicated to provide the best valuable PCB and assembly service with quality and low price

• PCB fab+Assembly Quick turn
  No Minimum Order Even 1 pcs
  Products Quality Warranty
  High Quality and Low Price

• Certified Quality Standards
  Reliable PCB Manfacturing
  Turnkey PCB assembly

Our Advanced Equipment

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• We offer both prototype and volume PCB production, also with turnkey PCB assembly service under one roof. We produce full specification include rigid, flex-rigid ,HDI boards up to 12 layers with trace/space as 4/4 mil, special specification like heavy copper, blind via, countersink, gold fingers etc.

Our Capabilities

PCB Materials

Zapon Use FR4 and Rogers Material for PCB fabrication

The standard FR-4 material that is used in our products is a high temperature. we also provide high TG 170 FR4 material.

Most printed circuit boards are manufactured using glass-reinforced epoxy laminate as the substrate. While there are a wide variety of laminates available on the market, FR-4 is both versatile and well-accepted as a standard material for PCB manufacture. FR-4 functions well as an electrical insulator, and has a good strength-to-weight ratio, and is flame resistant.

Whether it’s high-speed designs, RF, microwave, or mobile applications – where power management is key, you’re finding more situations that require dielectric PCB properties in your prototypes that standard FR-4 just can’t deliver. We know that. That’s why we have added more materials to our arsenal. One example of these added materials is Rogers 4000-series. These low-loss dielectric materials mean greater performance for your high-demand PCB prototypes or production.

we provide Rogers 4003C and 4350B with thickness 0.5mm and 0.8mm available

Impedance Controlled PCBs

Zapon provides stack-up and impedance calculations upon request. Our Field Application Engineers are ready to help you at anytime. We will work with your engineering team at the conceptual level of the PCB design to help you obtain better results in controlling impedance by selecting the proper material and layer stack up.

PCB Electrical Testing

We performs 100% electrical testing on all bare PCBs produced at its facilities as per IPC-9252 specifications. We use the Fixture method or the Flying Probe method to perform the testing in our circuit board manufacturing process.

To test the PCBs, we require the NETLIST file. Although we create a reference netlist from the customer’s original Gerber data, we always prefer to receive the CAD file based on the netlist for comparison. Since a CAD-based netlist is generated before PCB routing, it provides another layer of checking (against the Gerber output). This allows us to catch any shorts/opens introduced in the event of of an error in the Gerber files.

we give free testing for all boards more than 2 layers. We feel that Electrical Test is an essential component to the PCB ‘s manufacturing process, however in rare instances customers may determine that the added expense is not justified in particular situations. It is only to accommodate these situations that we break out this process as an option.

Our goal is to ship all boards with zero defects and Electrical Test is a critical part of this quality process. While Electrical Test will not eliminate the possibility of any defects being present on boards that you receive it will significantly reduce the likelihood.

PCB Files

Based on the software we use to process all orders, we accept the following PCB files as compressed zipped folders with all necessary files included: Gerber, ODB++, We also accept .pcbdoc files and .brd files from PCB Creator software, which we can then export as Gerber data. These PCB files must include a minimum of the following: all copper layers of the board, a drill file, and an outline layer, which may need to be exported separately.

Gerber files 274X files, NC drill files
Bottom copper layer ; Top copper layers; Inner layer1( for multi-layers); Inner layer2 (for multi-layers); silkscreen top; silkscreen bottom (if you have); top solder mask and bottom solder mask; Border layer( Layer used to define the shape of the board).

Delivery Times

Whether you require your project in a hurry or are just interested in the best value, we offer a variety of turnaround times to meet your needs. 2 Layer projects can be fabricated in 3 days Contact us for more info on PCB fab express options for your specific project.
for prototype, normally it will take 8 days , Production orders around 10-15days

Printed Circuit Boards FAQ

01. What is your laminate thickness options?

Our standard laminate thickness is 1.6 mm (0.063″).
We can also manufacture your boards with this non-standard laminate thickness: 0.2mm (0.0079″), 0.4mm (0.016″), 0.6mm (0.024″), 0.8 mm (0.032″), 1.0 mm (0.04″), 1.2mm (0.047″), 2.0mm (0.079″), 2.4mm (0.091″).3.0mm(0.118”).3.2(0.126”)

02. How do you keep your prices low?

We keep our prices low by constantly implementing more efficient manufacturing processes, developing systems that allow us to quickly change setups, maintaining partnerships with suppliers, and conservatively managing our business. Also the our factory is located in China, the labour cost is low in China.

03. What is V score Vs Tab-routing?

V scoring is probably faster and easier but has limitations. It only work with square shape, and V score line can only go from edge to edge. Once assembled the scored grooves can be sliced apart using what is sometimes called a pizza cutter type de-paneler or even snapped apart depending on design and how close the component lands are to the edge of the boards.

Tab routing can handle odd shapes but usually leaves nubs or small pieces of laminate on the edges that may need to be sanded off. Also, tab routing in high volumes takes a lot of time on the router and may drive your cost up.

If the vendor has scoring in house and the boards are square that would probably be the cheapest but if they have to send out for scoring that can drive up cost. Some tabs also have small holes drilled into them to help the breaking apart of the individual boards but again, this can drive up cost. If you use tab routing make sure you make the tabs big enough to be strong and make an array that can be handled but not so big that the boards cannot be broken apart.

04. How to reduce the cost of printed circuit board?

The PCB price is related with quantity ,size, min clearance, min hole size, and number of layers. If you just get the lowest price please design your board as simple as possible. For the standard spec of the PCB will be : 2 layers 0.062”, FR4 , 1oz, HAL, hole size>15mil, clearance>7mil, square shape, without slots

The following listed are the key factors but not limited:

Effective panelization – Some board sizes utilize up to 80% usability, some down to 50%. This would affect your price.

Number of holes the boards is drilled on sophisticated NC drilling machines. These machines are quite expensive and the machine time is expensive too, so less holes means less machine time for drilling and lower cost.

Number of hole sizes – the slowest operation in drilling is the tool exchange. Usually the boards are drilled at very high RPM values up to 60-80.000 rpm/min. To change the tool the machine has to stop the spindle, to wait until the tool stop rotating. To move to the drilling rack, to place the old tool, to get new tool, to move back to board drill position, to drive the spindle again and to wait the RPM value to reach the drill RPM set point for the new tool. Each tool change takes approximately the time for drilling 100-200 holes. Try to minimize the number of drill tools as much as possible. Combine the tools with difference only few mils if your holes will pass your required tolerances.

Trace width / space requirements – this is in close relation with the manufacturing yield. For instance if your traces are wide enough (>20mils) the board can be manufactured with etch resist single silkscreen printing operation instead of dry film lamination, exposure, developing.

Special board requirements, controlled impedances etc. – this affects again the manufacturing yields.