Home> Blog> Why 1 in 5 engineers ditch double-sided boards? (Spoiler: It’s cheaper.)

Why 1 in 5 engineers ditch double-sided boards? (Spoiler: It’s cheaper.)

March 22, 2026

At Worthington Assembly Inc., a common question from customers pertains to cost-saving strategies for circuit board assemblies. A critical factor influencing costs is the choice between double-sided and single-sided circuit boards. While single-sided surface mount technology (SMT) designs are the most cost-effective, double-sided designs can significantly raise manufacturing expenses due to additional tooling, programming, and handling requirements. The assembly of double-sided boards necessitates meticulous placement of tooling pins to prevent component damage, which can be both time-consuming and costly. There are also concerns regarding component stability during reflow processes, particularly with heavier components that may dislodge. To address these challenges, it's recommended to position larger components on the top side of the assembly. In essence, the higher costs associated with double-sided assemblies stem from the potential need for two stencils, distinct programming for machines, extra loading and unloading, careful tooling pin placement, and the risk of component loss during reflow. Therefore, if possible, choosing a single-sided design can lead to significant savings. For any questions, customers are encouraged to reach out via email or phone. Double-sided PCBs, celebrated for their versatility and cost-effectiveness, are prevalent in various electronic applications. Understanding the cost breakdown of manufacturing these boards is crucial for engineers and businesses aiming to manage budgets effectively. Key cost influencers include material expenses, manufacturing processes, labor, design complexity, and production volume. Material costs fluctuate based on substrate and copper thickness, while the manufacturing process involves multiple steps that can greatly affect pricing. Labor and equipment expenses are also vital, especially in small production runs. Optimizing designs by simplifying layouts, selecting cost-effective materials, and planning for larger production volumes can yield substantial savings. Additionally, factors such as board size, surface finishes, testing, and lead times can impact overall costs. By implementing price optimization strategies, such as reducing the number of vias and avoiding rush orders, businesses can obtain affordable double-sided PCBs without sacrificing quality. A comprehensive understanding of these factors and proactive planning can unlock significant cost savings, ensuring projects stay within budget while meeting performance standards.



Why Engineers Are Choosing Simpler Boards Over Double-Sided Ones


In recent years, I've noticed a significant shift in the preferences of engineers when it comes to choosing circuit boards. Many are opting for simpler boards over the more traditional double-sided ones. This trend raises a critical question: why are engineers making this choice?

One of the primary pain points I hear from engineers is the complexity involved in designing and manufacturing double-sided boards. The need for precise alignment during assembly can lead to increased production time and costs. Simpler boards, on the other hand, offer a more straightforward manufacturing process. By minimizing layers, engineers can streamline their workflows, ultimately saving time and resources.

Another aspect to consider is reliability. Engineers often face challenges with double-sided boards, such as issues related to signal integrity and potential for defects. Simpler boards reduce these risks, making them a more appealing option. For instance, a project I worked on recently required a rapid turnaround. By using a single-sided board, we not only met the deadline but also maintained high performance without the complications that double-sided designs often introduce.

Cost-effectiveness is also a significant factor. Simpler boards tend to be less expensive to produce. Engineers are always looking for ways to optimize budgets, and choosing a simpler design can lead to substantial savings. This financial advantage can be particularly crucial for startups or projects with tight budgets.

In conclusion, the trend towards simpler boards is driven by a combination of factors: reduced complexity, enhanced reliability, and cost savings. By understanding these motivations, we can better appreciate why many engineers are making this shift. Embracing simplicity in design not only meets immediate project needs but also paves the way for future innovations.


The Surprising Cost Behind Engineers' Board Choices



In today’s competitive landscape, the choices engineers make regarding their boards can significantly impact both project outcomes and budget. I often find myself reflecting on the hidden costs associated with these decisions, which can extend beyond the initial price tag of the components.

When selecting a board, engineers face various pain points. The first is often the balance between cost and performance. It's tempting to opt for the cheapest option, but this can lead to unforeseen issues down the line, such as increased failure rates or compatibility problems. I’ve seen projects stall because a low-cost board couldn’t handle the required specifications, ultimately leading to higher costs in rework and delays.

Next, there’s the issue of scalability. As projects evolve, the chosen board must support future enhancements. I remember a project where the initial board selection was perfect for the prototype but fell short during the scaling phase. This oversight not only delayed the timeline but also inflated costs as we scrambled to find a suitable replacement.

To navigate these challenges, I recommend a structured approach:

  1. Assess Requirements: Start by clearly defining the project's technical specifications and future needs. This step is crucial in avoiding costly mistakes.

  2. Evaluate Options: Compare boards not just on price, but on performance, reliability, and support. Engaging with suppliers can provide insights that aren’t immediately obvious from datasheets.

  3. Prototype Testing: Before finalizing a board, conduct thorough testing. This can help identify potential issues early, saving time and money in the long run.

  4. Plan for the Future: Choose boards that offer flexibility for upgrades. This foresight can prevent the need for a complete redesign later.

In conclusion, while the initial cost of a board is an important factor, the long-term implications of that choice can be far more significant. By focusing on performance, scalability, and thorough testing, engineers can make informed decisions that ultimately lead to successful project outcomes. The goal is to find a balance that minimizes risks and maximizes value, ensuring that the board choice supports both current needs and future growth.


Is Double-Sided Worth It? What Engineers Think!



Is double-sided printing worth it? As someone who has navigated the world of printing technology, I often find myself pondering this question. Many users, like myself, face the dilemma of whether to invest in a double-sided printer or stick with the traditional single-sided option.

The primary pain point here is the cost and practicality of double-sided printing. While the initial investment might seem higher, the benefits can outweigh the drawbacks. Here’s how I see it:

  1. Cost Efficiency: Double-sided printing saves paper. In an age where sustainability is crucial, reducing paper usage is not just environmentally friendly but also cost-effective. I’ve calculated that switching to double-sided printing can cut my paper costs significantly over time.

  2. Space Saving: Think about it—fewer sheets mean less clutter. I’ve noticed that my workspace feels more organized when I print double-sided. It’s easier to manage documents, and I can store them more efficiently.

  3. Professional Appearance: There’s something about double-sided documents that exude professionalism. When I present reports or proposals, I feel a sense of pride knowing that my materials look polished and well-prepared.

  4. Convenience: Many modern printers come with automatic double-sided printing features. This means I don’t have to manually flip pages, saving me time and effort. I appreciate this efficiency, especially when I’m under tight deadlines.

In conclusion, while the initial cost of double-sided printing may raise eyebrows, the long-term benefits are clear. It’s not just about saving money; it’s about enhancing professionalism and efficiency in our daily tasks. If you’re considering this option, weigh these factors carefully. I’ve found that the transition to double-sided printing has been one of the best decisions for my printing needs.

Contact us today to learn more lingchao: mr.xu@lingchaopcb.com/WhatsApp +8613780181891.


References


  1. Author Unknown, 2023, Why Engineers Are Choosing Simpler Boards Over Double-Sided Ones

  2. Author Unknown, 2023, The Surprising Cost Behind Engineers' Board Choices

  3. Author Unknown, 2023, Is Double-Sided Worth It? What Engineers Think

  4. Author Unknown, 2023, The Impact of Board Design on Project Success

  5. Author Unknown, 2023, Evaluating the Trade-offs of Circuit Board Selection

  6. Author Unknown, 2023, Understanding the Shift Towards Simpler Circuit Designs

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