PCB Capabilities
PCB Panelization
V-score and tab routing panel designs optimized for fabrication and assembly.
PCB panelization combines multiple individual board images into a single manufacturing panel for efficient fabrication and assembly. Proper panelization reduces fabrication cost, enables automated SMT assembly, simplifies handling during test and inspection, and ensures clean separation of individual boards after assembly. AstroPCB designs panelization layouts optimized for both fabrication yield and assembly throughput.
Why panelization matters
PCB fabrication equipment processes panels, not individual boards. A standard manufacturing panel is typically 18 x 24 inches (457 x 610 mm), though panel sizes vary by manufacturer. Small boards fabricated one at a time waste panel area and require individual handling at every process step. Panelization arrays multiple board images on a single panel, maximizing material utilization and minimizing per-board processing cost.
For assembly, panelization is equally important. SMT pick-and-place machines, reflow ovens, AOI systems and selective soldering equipment are designed to handle panels. Individual small boards cannot be reliably conveyed through automated assembly lines without a panel carrier. Even boards large enough for individual processing benefit from panelization when quantities justify the improved assembly throughput.
V-score panelization
V-score (V-groove) panelization cuts a V-shaped groove partially through the panel on both the top and bottom surfaces along the breakout line. The remaining material (typically 30-40% of the board thickness) holds the panel together during fabrication and assembly, then snaps cleanly when the boards are separated. V-score is the simplest and lowest-cost panelization method.
V-score works best for rectangular boards with straight breakout edges. The groove must run the full length or width of the panel — it cannot start or stop mid-panel. V-score is not suitable for boards with components or traces close to the board edge, because the breakout process leaves a rough edge with approximately ±0.1 mm dimensional tolerance. Keep components and traces at least 0.5 mm from the V-score line.
Tab routing (breakaway tabs)
Tab routing uses routed slots to separate individual boards within the panel, leaving small tabs (breakaway tabs) that hold the boards in place. The tabs are typically 2-3 mm wide and may include perforations (mouse bites) — a line of small drilled holes along the tab that weaken it for easy snapping. Tab routing accommodates irregular board shapes, cutouts and non-rectangular outlines that V-score cannot handle.
Tab placement requires design judgment. Tabs must be strong enough to hold the board in place during assembly (including the mechanical stress of wave soldering and depaneling) but weak enough to break cleanly without cracking the board. Place tabs at locations where the board edge has no components, connectors or sensitive traces. Avoid placing tabs at corners where stress concentration can crack the laminate.
Stamp-hole (perforation) panelization
Stamp-hole panels use a line of closely spaced drilled holes along the board perimeter to define the breakout boundary. The holes perforate the panel sufficiently that the boards can be pushed or bent out of the panel frame. Stamp-hole is sometimes combined with tab routing for hybrid panels that need both precise outline control and easy depaneling.
Panel design optimization
Optimal panelization balances several factors: maximum board count per panel (minimizing material waste), adequate panel rail width for conveyor handling (typically 5-10 mm on two opposing edges), fiducial mark placement for SMT machine alignment, tooling hole placement for fixture registration, and breakout method selection based on board geometry and edge tolerance requirements.
AstroPCB’s engineering team reviews panelization as part of the DFM process. When the customer provides a panelization layout, it is checked for fabrication and assembly compatibility. When no panelization is specified, the engineering team proposes an optimized layout based on the board dimensions, assembly requirements and quantity.
Request a panelized quote
Include your preferred panelization method (V-score, tab route, or let the engineering team recommend) with your design files. For assembly orders, specify which edges need conveyor rails and whether machine fiducials should be added to the panel.