As modern electronic systems become more compact and complex, the demand for multilayer HDI (High-Density Interconnect) PCBs continues to rise. A 10-layer HDI PCB offers advanced routing capabilities, high-speed signal integrity, and smaller footprints—making it essential in fields like aerospace, medical, and next-gen mobile devices.
But how much does it actually cost to build one in 2025?
In this guide, we’ll walk you through everything from material selection and regional price differences to real-world examples and hidden costs—equipping you with the knowledge to budget and source with confidence.
1. What Is a 10-Layer HDI PCB?
A 10-layer HDI PCB is a complex printed circuit board with 10 conductive layers, connected by high-precision vias such as blind, buried, and stacked microvias. It’s manufactured using laser drilling, multiple lamination cycles, and often includes features like via-in-pad.
Applications:
- Smartphones, tablets, and cameras
- Automotive radar and infotainment systems
- Aerospace navigation systems
- Medical implants and diagnostic equipment
2. Key Factors That Affect the Cost of 10-Layer HDI PCBs
Several factors significantly influence the final cost of a 10-layer HDI PCB:
- Material Type: FR4 Tg170 is standard, while high-frequency materials like Rogers or Megtron 6 can add $100–$300 per batch.
- Stackup Complexity: More lamination cycles and stacked microvias can raise costs by $50–$150.
- Surface Finish: ENIG may add $0.10–$0.50 per board compared to HASL.
- Board Size and Panel Utilization: Larger sizes and low panel yield increase per-unit cost.
- Quantity: Small prototype runs may cost $25–$70 per board, while high-volume orders can reduce costs below $20 per unit.
3. Global Price Range in 2025: What Buyers Are Paying
Here’s a breakdown of actual pricing for 10-layer HDI PCBs in 2025 by region and quantity:
| Region | Prototype (10 pcs) | Low Volume (100 pcs) | Mass Production (1,000 pcs) |
| USA | $480 – $700 total | $42 – $60 per unit | $28 – $38 per unit |
| Europe | $500 – $750 total | $45 – $65 per unit | $30 – $45 per unit |
| China | $260 – $450 total | $24 – $36 per unit | $15 – $28 per unit |
Tip: Chinese manufacturers like KingSunPCB offer 10-layer HDI prototype boards starting from $260 for 10 pieces with ENIG finish, 1.6 mm thickness, and standard FR4 Tg170.
Even with a competitive unit price, some “invisible” costs may catch you off guard:
- NRE Charges: Engineering/setup fees ($120–$300)
- Solder Mask and Surface Finish Adjustments: ~$0.05–$0.30 per board
- Testing: Flying probe or E-test can cost $0.05–$0.20 per board
- Freight and Import Duties: Add up to 10–15% for international shipments
- Yield Loss: HDI yields are typically lower due to manufacturing complexity
5. Real-World Pricing Examples from Suppliers
Example 1: USA Supplier – Quickturn Prototypes
- Specs: 10 pcs, 50mm x 50mm, ENIG, stacked vias
- Price: $680 total ($68/pc)
- Lead Time: 10 working days
Example 2: Chinese Supplier – Mid-Volume Order
- Specs: 100 pcs, 100mm x 100mm, FR4, staggered vias
- Price: $2,800 total ($28/pc)
- Lead Time: 7 working days
Example 3: EU Aerospace-Grade Supplier
- Specs: 100 pcs, tight impedance control, via-in-pad
- Price: $4,800 total ($48/pc)
- Certifications: IPC Class 3, ISO 13485
6. How to Reduce Your 10-Layer HDI PCB Costs
Here are practical ways to reduce your costs, with real dollar impact:
| Strategy | Estimated Savings |
| Replace stacked vias with staggered | Save $30–$80 per 10 pcs |
| Use HASL instead of ENIG if specs allow | Save $0.20–$0.50 per unit |
| Optimize panel layout and size Save | Save 10–15% per batch |
| Extend lead time (avoid express fees) | Save $50–$100 per order |
| Order in higher volumes | Lower cost by up to 40% per unit |
Example: A design using stacked vias and ENIG finish might cost $700/10pcs, but redesigning for staggered vias and HASL could drop the price to $550—saving ~$150 instantly.
7. How Application Affects Pricing
Depending on where your 10-layer HDI PCB will be used, your price point can vary significantly:
Medical Devices (implantable, wearable): Requires ISO 13485 + biocompatible materials
- Price Range: $40 – $65 per unit
Aerospace & Defense (Class 3, zero-defect standards): Involves traceability, conformal coating
- Price Range: $45 – $75 per unit
Automotive & Industrial Control (high-temperature, vibration-tolerant): Needs advanced materials
- Price Range: $28 – $50 per unit
Consumer Electronics (phones, drones, IoT): Large volume, cost-sensitive
- Price Range: $15 – $30 per unit
8. Choosing a Reliable HDI PCB Manufacturer
When sourcing complex HDI PCBs, your supplier must deliver more than just price:
- Experience with multilayer, stacked via fabrication
- Fast and accurate stackup design review
- English-speaking support and flexible payment options
- Certifications: ISO 9001, RoHS, UL, IPC-6012
Why Choose KingSunPCB?
KingSunPCB is a trusted China-based manufacturer specializing in high-density, multilayer PCB fabrication:
- 10-layer HDI prototype from $260 / 10 pcs
- Advanced via-in-pad and laser via technology
- 24-hour engineer response and stackup consulting
- 7–10 day turnaround and global shipping
Request a quote now and receive free design optimization and DFM review!
9. Conclusion: Final Thoughts on 10-Layer HDI PCB Pricing
A 10-layer HDI PCB is an investment in performance and design flexibility—but it doesn’t have to break your budget. By understanding global pricing benchmarks, the impact of technical choices, and where hidden costs lie, you can confidently manage your PCB procurement.
Whether you’re building prototypes or scaling to volume, partnering with a manufacturer like KingSunPCB can help you achieve both reliability and cost-efficiency.