Castellated PCBs—also known as half-hole or edge-plated boards—are increasingly used in modular electronics such as IoT modules, wireless transmitters, GPS units, and embedded controllers. They allow easy soldering between two PCBs and ensure compact, reliable electrical connections.
Understanding Castellated PCB cost structure is essential for OEM buyers and engineers who need to balance performance and budget. In this article, we’ll analyze all the major cost factors and show how KingsunPCB, a professional PCB manufacturer in China, provides high-quality castellated PCBs at competitive prices.
1. What Is a Castellated PCB?
A Castellated PCB, also known as a half-hole PCB or edge-plated PCB, features small plated holes cut through the edges of the board. These “castellations” allow seamless soldering between two PCBs, making them ideal for IoT modules, wireless communication devices, and embedded systems.
Compared with traditional PCBs, castellated designs offer:
- Compact board-to-board connection
- Easy soldering during assembly
- Reliable mechanical alignment
However, due to the precise routing and drilling required, castellated PCB manufacturing costs can be slightly higher than standard PCBs.
2. Key Factors That Affect Castellated PCB Pricing
2.1 Board Size, Shape, and Layer Count
Larger or irregularly shaped PCBs require more base material and machining time.
- 2-layer castellated PCB: $0.8–$2 per unit
- 4-layer castellated PCB: $2–$4 per unit
- 6-layer castellated PCB: $3–$6 per unit
2.2 Base Material Type and Quality
- FR4: Most common and cost-effective ($0.80–$2/pc)
- Rogers: For RF and high-frequency applications (+30–50% cost)
- Ceramic: Premium thermal stability, priced at $5–$10 per board
2.3 Copper Thickness and Surface Finish
Copper thickness affects both electrical performance and cost.
- 1 oz copper: Standard thickness, economical
- 2 oz copper: Adds 20–30% to total cost
Surface finish cost comparison:
- HASL (Hot Air Solder Leveling): $0.80–$1.50/pc
- ENIG (Electroless Nickel Immersion Gold): $2–$3/pc
2.4 Hole Size, Pitch, and Precision
- Smaller castellated holes (≤0.6 mm) demand tighter CNC control and longer milling time, increasing cost by 10–15%.
2.5 Quantity and Production Volume
Unit cost decreases significantly with larger quantities:
- Prototype (1–10 pcs): $50–$120 total
- Small batch (100–500 pcs): $0.80–$3 per unit
- Mass production (1,000+ pcs): $0.40–$1.50 per unit
2.6 Lead Time and Turnaround Speed
- Faster manufacturing incurs additional fees (typically +15–25%).
KingsunPCB offers quick-turn castellated PCB fabrication within 24–72 hours, starting at just $80 for 10 pieces, ideal for urgent prototyping needs.
3. Additional Cost Influences Beyond Manufacturing
3.1 Regional Manufacturing Differences
PCB prices vary widely across regions:
- China (KingsunPCB): $0.40–$2/pc
- U.S. / Europe: Typically 2–3× higher due to labor and energy costs
This makes China-based suppliers like KingsunPCB the best option for low-cost castellated PCB fabrication with consistent quality.
3.2 Supply Chain and Material Availability
Global raw material costs—especially copper—affect PCB pricing by 5–15%. KingsunPCB’s long-term partnerships with top material suppliers help stabilize pricing and ensure timely production.
3.3 Design Complexity and Engineering Support
High-density castellations or tight-tolerance layouts may increase setup costs. KingsunPCB provides free DFM (Design for Manufacturability) reviews to minimize rework and reduce cost.
3.4 Testing and Quality Assurance
Electrical and AOI testing add $0.10–$0.30 per board, but they prevent costly defects in the long run.
3.5 Packaging, Logistics, and Export Costs
Shipping and customs can affect the final landed cost by up to 10–20%. KingsunPCB offers consolidated international shipping, helping customers lower logistics expenses.
4. Average Castellated PCB Price Range
| Production Type | Quantity Range | Typical Unit Price (USD) | Notes |
| Prototype | 1–10 pcs | $50–$120 total | Includes setup and express service |
| Small Batch | 100–500 pcs | $0.80–$3 per unit | Ideal for pilot runs |
| Mass Production | 1,000+ pcs | $0.40–$1.50 per unit | Lowest price per board |
With KingsunPCB’s optimized production and material sourcing, customers can save up to 35–45% compared with Western PCB suppliers.
5. How to Reduce Castellated PCB Manufacturing Costs
- Simplify layout to minimize the number of castellations
- Use standard FR4 materials and 1 oz copper
- Panelize multiple designs to reduce setup cost
- Plan bulk orders to unlock volume discounts
Choose KingsunPCB, a China-based PCB manufacturer offering high-quality castellated boards starting at $0.40 per piece
6. Why Choose KingsunPCB for Castellated PCB Fabrication
KingsunPCB has over 15 years of experience producing high-precision PCBs, including castellated-edge designs.
Key Advantages:
- Precision CNC edge routing for accurate castellations
- Competitive China factory pricing (from $0.40 per board for bulk orders)
- Free design review and instant quotation
- 24–72h quick-turn prototype service (as low as $80 for 10 pcs)
- Global shipping and quality assurance with ISO-certified facilities
KingsunPCB delivers cost-effective solutions without compromising quality — making it a top choice for castellated PCB manufacturing worldwide.
7. Conclusion
Castellated PCB pricing depends on multiple factors such as design complexity, materials, quantity, and lead time. By understanding these elements and working with a reliable manufacturer like KingsunPCB, engineers and OEMs can effectively reduce production costs while ensuring performance and durability.
Get your instant quote today at KingsunPCB.com — factory-direct prices starting from $0.40 per unit.
8. FAQ: Common Questions About Castellated PCB Pricing
Q1: How much does a 2-layer castellated PCB cost in 2025?
On average, $0.80–$2 per piece for small runs, or as low as $0.40 per unit for large-volume production from KingsunPCB.
Q2: Why are castellated PCBs slightly more expensive than regular PCBs?
Because the edge-plating process and half-hole milling require extra precision and setup time during production.
Q3: Can KingsunPCB provide express castellated PCB fabrication?
Yes! KingsunPCB offers 24–72 hour express service, with prototype pricing starting from $80 per batch (10 pcs).
Q4: Which surface finish is most cost-effective?
HASL is the most budget-friendly finish, while ENIG offers superior oxidation resistance for an additional $1–$2 per board.
Q5: How can I get an accurate cost quote?
Simply upload your Gerber files and order requirements on KingsunPCB’s website to get a real-time price estimate including material, thickness, and turnaround options.