A PCBA quote has two parts: the recurring cost per board and the non-recurring engineering (NRE) charged once. The NRE is where quotes differ most, because suppliers bundle different items into it.
This article breaks down what NRE usually includes, what drives each item, and when you should expect it to be amortized.
What NRE covers
- Stencil. A laser-cut stainless sheet for solder paste printing, mounted in a frame.
- Test fixture. A bed-of-nails or functional fixture for ICT/FCT, built for your board.
- Programming. Firmware loading, IC programming, or configuration during assembly.
- First article inspection (FAI). Dimensional, visual and X-ray checks on the first boards.
- Tooling and setup. Pick-and-place programming, reflow profile, AOI recipe.
- Documentation. Build package, work instructions, traceability setup.
For a simple board, NRE may be one stencil and a setup fee. For a complex board with test requirements, it can be several thousand dollars.
Stencil
The stencil controls paste volume, which controls solder joint quality. Key choices:
- Thickness. Usually 0.10–0.15 mm, matched to the finest pitch and the largest component.
- Laser cut vs electroformed. Laser is standard; electroformed is used for fine pitch and high volume.
- Frame. Reusable frame or frameless; framed stencils are more durable.
- Step stencil. Needed when a board mixes fine pitch and high-pin-count connectors.
A stencil is cheap relative to a fixture, typically tens to a few hundred dollars. It is also consumable: it wears and is replaced periodically.
Test fixture
A fixture is the largest NRE item for boards that need 100% test. It includes:
- Probe pins and a bed-of-nails plate.
- A fixture base and clamps.
- Wiring to the tester.
- A test program.
Cost depends on board size, net count, probe density and whether the fixture is ICT, FCT or both. A small board with a few hundred nets may need a fixture in the high hundreds; a dense board with thousands of nets can exceed several thousand.
If volume is low, flying probe test may avoid the fixture entirely. That trade-off is usually worth checking before accepting a fixture charge.
Programming and first article
Programming is charged when the assembler loads firmware or programs an IC. It includes the setup and the risk of a wrong image.
First article inspection is the evidence that the process is correct before volume. It should include:
- Solder joint inspection under magnification.
- X-ray of BGA and QFN.
- Cross-section if the spec requires it.
- Functional check.
- A report with photos and measurements.
FAI is not optional for safety-critical or automotive boards. For simple consumer boards it may be replaced by AOI plus a functional check.
When NRE is amortized
Suppliers sometimes waive NRE above a quantity threshold. Ask three questions:
- Is the NRE one-time or per revision?
- Is the stencil included, and who owns it?
- Is the fixture included, and can it be reused for the next build?
A quote with low NRE and higher unit price may cost more over the program. A quote with high NRE and low unit price may be better if the design is stable.
| Item | Typical range | Main driver |
|---|---|---|
| Stencil | Tens to a few hundred USD | Size, step, frame |
| Test fixture | Hundreds to several thousand USD | Nets, density, test type |
| Programming | Per hour or per unit | Setup, image count |
| FAI | Included or per report | X-ray, cross-section |
| Setup | Per build | Line changeover |
Cost levers
- Reduce net count where possible; it lowers fixture cost.
- Use flying probe for low volume instead of a fixture.
- Standardize stencil frames across builds.
- Keep revisions to a minimum; each revision may repeat NRE.
- Ask what is included in FAI, not only the price.
FAQ
Is NRE always charged separately?
No. Some suppliers include it in the unit price. Ask for the breakdown so you can compare quotes.
Who owns the stencil and fixture?
Usually the assembler, unless the contract says otherwise. If you pay for them, ask for ownership or a transfer clause.
Can I reuse a fixture for a revision?
Sometimes, if the probe points and board outline do not change. Any layout change usually requires a new fixture.
Is FAI required for every order?
No. It is required for new builds, new revisions and safety-critical products. For repeat orders, AOI and functional test may be enough.
NRE is negotiable in a way unit price is not. Send the build package with the annual volume, and we will separate one-time tooling from per-revision charges so the comparison against another quote is like for like.
