As the demand for high-volume PCB assembly grows, manufacturers continue to seek methods that improve efficiency, reduce costs, and ensure consistency. One such method is array panelization—a widely adopted practice where multiple PCBs are assembled together on a single panel using automated equipment. Once assembled, these individual boards are depanelized or separated for integration into products or for packaging.

While array panels may appear uniform, proper panel design is critical for successful assembly. At Gelco Electronics, we believe that understanding these panel requirements is key to optimizing the entire production process. Here’s an overview of what you need to know.

Why Panelization Matters

Panelization plays a critical role in streamlining the PCB assembly process, especially in high-volume production. By grouping multiple boards into a single panel, manufacturers can maximize efficiency during handling, component placement, and soldering. This not only reduces manual labor but also minimizes setup time for machines, leading to faster turnaround and lower production costs. Additionally, panelization helps improve yield and quality control by allowing for uniform processing of multiple boards under the same conditions. It also simplifies testing and debugging, as entire panels can be tested simultaneously before boards are depanelized. Overall, panelization contributes to better resource optimization, higher throughput, and greater consistency in PCB manufacturing—making it an essential practice in modern electronics assembly.

Key Panel Requirements for PCB Assembly

• Panel Size: The size of the panel plays a crucial role in ensuring compatibility with automated assembly equipment such as pick-and-place machines and reflow ovens. Commonly used panel dimensions include 12×9, 12×18, 24×9, and 24×18 inches. Selecting the right panel size based on board layout and quantity helps optimize space utilization and streamlines the assembly process.
• Types of Panel Designs: Depending on the production volume and application needs, manufacturers can choose between single-up and multi-up PCB panels. Single-up panels contain a single board per panel and are generally used for prototyping or low-volume production. On the other hand, multi-up panels contain multiple identical boards and are ideal for high-volume assembly as they enhance throughput and reduce per-unit costs.
• Depanelization Techniques: The method used to separate individual boards from a panel significantly impacts efficiency and board integrity. V-cut (or V-groove) panels are the most common and allow for easy snapping of boards. For these, a spacing of 0.3mm between boards and a 30° cut angle is recommended. Tab-route panels come in two styles: with or without perforated breakaway holes. When using holes, they should be 0.55–0.6mm in diameter, with at least 0.25mm spacing and six holes per tab. A combination of V-cut and tab routing is also used to offer additional strength and flexibility during depanelization.
• Fiducial Markers: Fiducials are reference points on the PCB that guide automated machinery during assembly. Global fiducial markers are placed on the panel’s edges to determine overall board orientation, while local fiducials are located near high-precision components to aid in accurate component placement. Proper fiducial design ensures alignment accuracy and reduces placement errors during high-speed operations.
• Tooling Holes: Tooling holes are used to align and secure the panel during various stages of the assembly and manufacturing process, including drilling, printing, and component placement. These holes are typically non-plated and located at the corners or edges of the panel. Though there is no fixed standard size, tooling holes must be consistently sized and positioned for reliable registration with automated equipment.

Trust Gelco Electronics for Smart PCB Panelization

At Gelco Electronics, we understand that efficient PCB manufacturing starts with intelligent panel design. Whether you’re building for high-volume production or specialized applications, our engineering team can help you select the optimal panelization strategy—from V-cuts to tab routes, fiducial placement, and more.

Looking to scale your PCB assembly efficiently and cost-effectively? Let Gelco Electronics help you meet your panelization and assembly goals with precision.