Castellation PCBs, also known as castellated hole PCBs, are widely used in wireless communication modules, IoT devices, RF modules, GPS trackers, Bluetooth products, Wi-Fi modules, Zigbee systems, and embedded electronics. Their unique edge-plated half-holes allow one PCB module to be directly soldered onto another, reducing connector costs while improving assembly efficiency.
However, because castellation PCBs require additional routing, precision drilling, copper plating, and edge milling, they generally cost more than standard FR4 PCBs.
So, how much does a castellation PCB cost in 2026?
The answer depends on several factors, including PCB material, layer count, board size, surface finish, copper thickness, production volume, manufacturing tolerances, and testing requirements.
This guide provides a detailed cost breakdown with realistic USD price ranges to help engineers and purchasing managers estimate project budgets accurately.
1. What Is a Castellation PCB?
A castellation PCB features half-plated through holes located on the PCB edge. After routing, each plated hole is cut in half, creating semi-circular solderable pads.
Compared with traditional board-to-board connectors, castellation technology offers:
- Lower assembly cost
- Compact product size
- Better electrical performance
- Excellent mechanical strength
- Faster SMT production
- Easier module replacement
Common applications include:
- Wi-Fi Modules
- Bluetooth Modules
- GSM Modules
- GPS Modules
- LoRa Devices
- RF Communication Modules
- Industrial IoT Sensors
- Medical Electronics
- Smart Home Products
2. Average Castellation PCB Cost in 2026
Below are typical manufacturing prices for standard FR4 castellation PCBs.
| PCB Type | Typical Price (USD) |
| 2-Layer Prototype (5 pcs) | $35–$80 |
| 2-Layer Small Batch (100 pcs) | $180–$450 |
| 4-Layer Prototype | $90–$180 |
| 4-Layer Production | $600–$1,500 |
| 6-Layer RF PCB | $1,200–$3,500 |
| High-Frequency Rogers PCB | $2,000–$8,000 |
| Flexible Castellation PCB | $800–$5,000 |
Actual pricing varies depending on board dimensions, process complexity, and order quantity.
3. Material Cost Breakdown
PCB material has one of the greatest impacts on manufacturing cost.
FR4 Material
The most economical option.
Typical cost increase:
- Base cost
- Excellent for consumer electronics
- Suitable for Bluetooth modules
- Suitable for IoT devices
Estimated price: $35–$120 for prototype orders.
High TG FR4
Designed for higher thermal reliability.
Price increase: Approximately 10%–20% higher than standard FR4.
Typical projects:
- Automotive electronics
- Industrial control
- LED drivers
Rogers Material
Ideal for RF and microwave applications.
Cost increase: Typically 2–5 times higher than FR4.
Prototype prices: $180–$600
Mass production: Several thousand dollars depending on board size.
Ceramic PCB
Used in extremely high-temperature or high-power electronics.
Price: Usually 3–8 times the cost of standard FR4.
4. Layer Count vs Cost
Additional layers require more lamination cycles, alignment accuracy, drilling, and inspection.
| Layers | Typical Prototype Cost |
| 2 Layer | $35–$80 |
| 4 Layer | $90–$180 |
| 6 Layer | $180–$350 |
| 8 Layer | $300–$700 |
| 10 Layer | $600–$1,500 |
Every additional lamination cycle increases production cost.
5. How Castellation Manufacturing Increases Cost
Unlike ordinary PCBs, castellation PCBs involve several specialized manufacturing processes.
5.1 Precision Drilling
The holes must align perfectly with the PCB edge.
Additional cost: Approximately 5%–10%.
5.2 Copper Plating
Each hole requires reliable copper plating before routing.
Additional cost: $20–$100 depending on quantity.
5.3 CNC Edge Milling
The routed edge must expose exactly half of every plated hole.
Cost increase: Approximately 10%–15%.
5.4 Extra Inspection
Manufacturers inspect:
- Hole integrity
- Copper thickness
- Edge smoothness
- Solderability
Quality inspection increases labor costs.
5.5 AOI & Electrical Testing
Most castellation PCBs receive:
- AOI Inspection
- Flying Probe Test
- Electrical Testing
Testing cost: $50–$300 depending on batch size.
6. Surface Finish Cost Comparison
Surface finish affects solderability, reliability, and price.
| Surface Finish | Cost Level |
| HASL | Lowest |
| Lead-Free HASL | Low |
| OSP | Low |
| Immersion Tin | Medium |
| Immersion Silver | Medium |
| ENIG | High |
| Hard Gold | Highest |
Typical price increase:
- HASL: Base cost
- OSP: +5%
- Immersion Silver: +8%
- ENIG: +10%–20%
- Hard Gold: +30%–60%
For wireless modules, ENIG is usually recommended because it provides excellent solderability and a flat surface for SMT assembly.
7. PCB Thickness and Copper Weight
Thicker boards require more material and longer processing time.
Typical cost increase:
Board Thickness
- 0.8 mm → Base
- 1.0 mm → +5%
- 1.6 mm → Standard
- 2.0 mm → +10%
- 3.2 mm → +20%
Copper Thickness
- 1 oz → Base
- 2 oz → +10%
- 3 oz → +20%
- 4 oz → +35%
8. Quantity Has the Largest Impact on Price
Prototype orders have high setup costs.
5 Pieces
Unit price: Approximately $12–18 each
100 Pieces
Unit price: Approximately $3–6 each
1,000 Pieces
Unit price: Approximately $0.80–2.50 each
10,000 Pieces
Unit price: As low as $0.30–1.20 each, depending on board size and complexity.
Economies of scale significantly reduce the cost per board.
9. Prototype vs Mass Production
Prototype
Characteristics:
- Engineering setup
- CAM programming
- Tooling
- Fast delivery
Price: $50–$300
Lead time: 3–7 days
Mass Production
Characteristics:
- Automated production
- Better material utilization
- Lower unit cost
Typical order: 1,000–100,000 pcs
Lead time: 2–5 weeks
Many buyers focus only on PCB fabrication costs but overlook additional expenses, including:
- Engineering review (DFM): $30–$200
- Tooling and fixtures: $100–$500
- Stencil for SMT assembly: $25–$120
- Functional testing: $100–$800
- X-ray inspection (BGA modules): $80–$500
- Express shipping: $40–$300
- Import duties and taxes (varies by destination)
Factoring in these costs early can help avoid budget overruns and ensure a smoother production schedule.
11. How to Reduce Castellation PCB Manufacturing Costs
You can lower overall project costs without sacrificing quality by following these best practices:
- Use standard FR4 whenever RF performance allows.
- Keep the layer count as low as practical.
- Minimize the number of castellated holes.
- Choose standard board thicknesses (such as 1.6 mm).
- Use panelization to improve manufacturing efficiency.
- Increase order quantities to reduce the unit price.
- Avoid unnecessary tight tolerances.
- Select standard surface finishes unless your application requires premium options.
- Work with an experienced manufacturer to optimize your design for manufacturability (DFM).
12. Why Choose KingSunPCB for Castellation PCB Manufacturing?
KingSunPCB specializes in precision castellation PCB fabrication for demanding industrial and commercial applications.
Our capabilities include:
- Precision edge routing with tight tolerances
- Reliable half-hole copper plating
- 2–20+ layer PCB manufacturing
- FR4, High TG, Rogers, Aluminum, Ceramic, and Hybrid materials
- ENIG, Hard Gold, OSP, HASL, Immersion Silver, and other surface finishes
- Prototype, low-volume, and mass production services
- AOI, Flying Probe, E-Test, and X-ray inspection
- Fast turnaround from prototype to full-scale production
- Competitive global pricing with engineering support
Whether you are developing an IoT module, RF communication device, medical system, or industrial controller, KingSunPCB can deliver cost-effective, high-quality castellation PCBs tailored to your project.
13. Frequently Asked Questions
Q1: Why are castellation PCBs more expensive than standard PCBs?
Because they require precision edge drilling, copper plating, CNC routing, and additional quality inspections to ensure reliable solderability and mechanical strength.
Q2: Does the number of castellated holes affect the price?
Yes. More castellated holes increase drilling, plating, routing, and inspection time, which raises manufacturing costs.
Q3: What is the cheapest material for castellation PCBs?
Standard FR4 remains the most cost-effective choice for most consumer electronics and IoT applications.
Q4: Is ENIG worth the additional cost?
For modules that require reliable SMT soldering, repeated reflow cycles, or long-term corrosion resistance, ENIG offers excellent value despite its higher price.
Q5: How can I get the lowest unit price?
Ordering larger production volumes, using standard materials and finishes, simplifying the design, and panelizing the PCB are the most effective ways to reduce per-unit costs.
14. Conclusion
The cost of a castellation PCB in 2026 depends on far more than just board size. Material selection, layer count, castellated hole quantity, surface finish, copper thickness, testing requirements, and production volume all contribute to the final price.
For simple 2-layer FR4 prototypes, costs typically start around $35–$80, while complex multilayer RF or Rogers-based designs can exceed $8,000 for production runs. By understanding these cost drivers and partnering with an experienced manufacturer like KingSunPCB, engineers and procurement teams can balance performance, reliability, and budget to achieve the best overall value.