Printed circuit boards (PCBs) form the backbone of electronics products and enable functioning of systems across every industry. From consumer devices to automotive to aerospace, PCBs provide the foundation to mount and interconnect electronic components. For companies developing hardware products, partnering with a reliable PCB manufacturing partner is crucial for success.
The USA has a robust PCB manufacturing industry comprising large global manufacturers as well as specialized domestic producers. In this comprehensive guide, we explore the top 10 PCB manufacturers in the USA along with a detailed overview of capabilities, technologies, trends and benefits of domestic PCB production.
Overview of PCB Manufacturing
Let’s first briefly understand what PCB fabrication involves. PCB manufacturing can be grouped into three main steps:
1. Design and Layout
The PCB layout is designed using EDA (electronic design automation) software like Altium, Cadence, Zuken based on circuit requirements. Engineers create schematics, route board traces, specify stackup, materials, finishes and other parameters.
2. Fabrication
The board fabrication process converts design files into physical boards. Key steps include:
- Imaging – Photoresist layers are coated on copper clad laminate and imaged using lithography to create pattern.
- Etching – Chemical etching removes unwanted copper leaving only desired traces.
- Layer Alignment – Drilled holes are aligned across layers, plated and via formed.
- Lamination – Layers of pre preg dielectric are stacked up and laminated under heat and pressure.
- Finishing – Outer layers are coated with soldermask and silkscreen. Edges trimmed, routed and finished.
3. Assembly
In PCB assembly, components like ICs, resistors, capacitors are soldered to the board. This is done either manually or using automated SMT assembly lines. PCB assembly can involve:
- SMT Assembly – Surface mount components placed and soldered to pads on the board.
- Through hole assembly – Leaded components inserted into drilled holes.
- Box build – Enclosure, cabling, accessories combined with assembled PCB.
- Testing – Electrical testing performed to ensure functioning.
This is a simplified overview of the PCB fabrication and assembly process. We will now look at major manufacturers providing these services in the US.
Top 10 PCB Manufacturers in USA
Here are the leading printed circuit board manufacturers located in the United States along with their capabilities and specializations:
1. TTM Technologies
TTM Technologies is one of the top PCB manufacturers globally with revenues exceeding $2 billion. Founded in 1998, they operate over 25 specialized PCB production facilities across the world including several in the USA.
Their US facilities are located in:
- Stafford Springs, CT
- Chippewa Falls, WI
- Santa Ana, CA
- San Jose, CA
- Logan, UT
- Boston, MA
- Oregon City, OR
With cutting edge equipment and processes, TTM provides the complete range of PCB manufacturing solutions from prototypes to high volume production:
Capabilities
- Rigid, flex, rigid-flex PCBs
- High Density Interconnect (HDI)
- Complex multilayer boards
- Advanced RF/microwave boards
- Miniaturized circuits
- Quick Turn prototypes
Technologies
- Line width/spacing down to 2 mil
- Stackups up to 30 layers
- Materials including FR4, Rogers, polyimide
- Blind and buried vias, microvias
- Embedded passives and components
- CEM-1, -3 approved
- Flex and rigid-flex
- Heavy copper, thick copper
Industry Focus
TTM caters to high reliability sectors including:
- Aerospace and defense
- Automotive and transportation
- Medical
- Industrial
- Networking/communications
With one of the largest PCB manufacturing footprints in North America, TTM provides advanced technology solutions from engineering to prototyping to volume production.
2. Sanmina Corporation
Sanmina (NASDAQ: SANM) is a leading integrated manufacturing solutions company providing end-to-end product lifecycle services. Their capabilities encompass PCB fabrication, enclosures, precision machining, systems integration and complete product assembly.
Some key facts about Sanmina:
- 2018 revenue of $12 billion with 43,000 employees.
- Over 25 manufacturing sites in the United States.
- Top 50 global EMS provider.
- Vertically integrated manufacturing from components to complete products.
PCB Manufacturing
- Prototype to high-volume PCB production
- Rigid, flex, rigid-flex
- 24+ layer count multilayer boards
- Line width/space to 3 mil
- Quick turn fabrication in 5 days
- Detailed DFM analysis
Assembly
- SMT, through-hole and manual assembly
- Conformal coating, potting, dispensing
- Machined, sheet metal, plastics enclosures
- Complex system integration
- Testing capabilities
- Fulfillment, warehousing and repair
Industry Segments
- Medical
- Defense and aerospace
- Industrial
- Multimedia and computing
- Communications networks
- Automotive
Sanmina provides a complete end-to-end manufacturing solution. Their advanced technologies and processes enable high reliability product realization from prototyping through new product introduction and volume ramps.
3. NCAB Group
NCAB Group is a Swedish PCB producer with a strong US presence through its NCAB NA subsidiary. NCAB operates a network of factories across China, but has sales teams and technical support in the major markets it serves.
In the USA, NCAB runs multiple production sites:
- 2 factories in California
- 1 facility in Illinois
NCAB offers:
- Short lead times for prototypes in 5-15 days
- Small and medium volume PCB production
- Rigid, flexible, HDI, rigid-flex boards
- Support for quick ramps and NPI phase
- Seamless transfer from prototyping to volume production
The company focuses on catering to the needs of startups and engineers needing fast turnaround on lower volume orders. With operations located in the major hubs for electronics innovation, NCAB is well positioned to support hardware companies.
4. Sierra Circuits
Sierra Circuits is a dedicated PCB manufacturer located in Sunnyvale, California specializing in rapid prototyping and quickturn fabrication. They produce over 5,000 unique PCB designs every year in their 165,000 square feet facility.
Capabilities
- 2 to 24 layer PCBs
- Line width and spacing to 3/3 mil
- Microvias, blind and buried vias
- Flex and rigid-flex PCBs
- Stiffeners, bezels and metal backings
- Assembly and box build assistance
Services
-24 hour rapid turn prototypes -ITAR registered and compliant -AS9100 certified -IATF 16949 certified -MIL-PRF-31032 certified -Design for Manufacturing guidance -Seamless transition to volume
Focus Areas
- Aerospace and defense
- Semiconductor
- Medical
- Automotive
- Instrumentation
With its capabilities for precision multilayer PCBs combined with extremely quick turns, Sierra Circuits delivers advanced solutions from prototyping to pre-production volumes.
5. Advanced Circuits
Based in Aurora, Colorado, Advanced Circuits is a leading PCB manufacturer catering to prototype and small volume production. They offer:
- Prototype PCBs in as fast as 24 hours
- Medium volume production runs
- Min order quantity of just 1 board
- Rigid PCBs with 10 to 36 layers
- Flex and rigid-flex boards
- FR4, Rogers, polyimide, Arlon materials
- ITAR registration for defense work
- Free DFM analysis
- PCB assembly through network
Advanced Circuits combines a quickturn fabrication model with small order volumes desired by design engineers and startups. Their online tools make PCB manufacturing convenient.
6. Calumet Electronics
Calumet Electronics, headquartered in Milwaukee, Wisconsin, manufactures a range of PCB types:
Rigid PCBs
- High layer count metal core boards
- RF/microwave boards
- Double-sided and multilayer FR4
- Quick turn prototypes
Rigid-Flex
- Flexible and multilayer rigid-flex
- Flex-rigid-flex configurations
- High density interconnect
Assembly
- SMT and through-hole assembly
- Lead-free assembly
- Box build services
- Design and fabrication
Markets
- Defense
- Medical
- Communications
- Industrial
Calumet provides advanced domestic PCB manufacturing coupled with assembly for high mix, low volume applications.
7. Murrietta Circuits
Murrietta Circuits has been manufacturing printed circuit boards for hi-reliability industries since 1980. They focus on quickturn fabrication for defense, aerospace, telecommunications and medical applications. Their key capabilities include:
Technologies
- Multilayer, metal core, flex, rigid flex
- High frequency RF materials
- Quick turn prototypes (5 days)
- Blind and buried vias
- High layer counts (26+)
Quality
- ITAR registered
- AS9100 and ISO 9001
- Mil-Prf-31032
- IPC 6012 Class 3
Volumes
- Prototypes
- Low to medium production
Services
- First article inspection
- IST testing
- Flying probe testing
- Full turnkey assembly
Based in Anaheim, California, Murrietta Circuits delivers advanced PCB solutions meeting stringent quality and documentation needs of regulated industries.
8. American Standard Circuits
Headquartered in Chicago, Illinois, American Standard Circuits is a full-service PCB manufacturer providing:
- Prototype through production PCB volumes
- Rigid, rigid-flex, metal-backed PCBs
- Quickturn and standard delivery options
- 2 week production cycles
- ITAR registered and compliant
- IATF 16949 and ISO 9001 certified
- Full assist services from DFM to assembly
Their manufacturing capabilities include:
- 8 metal layer PCBs
- .5mm line/space traces
- Panel sizes up to 60” x 80”
- Blind and buried vias
- ENIG, hard gold, immersion silver finishes
- Flex and rigid-flex boards
- SMT and through hole assembly
American Standard Circuits provides advanced domestic PCB and assembly solutions tailored for regulated industries like medical, defense and automotive.
9. Plasmatreat USA
Plasmatreat is headquartered in New Hampshire and provides PCB manufacturing, assembly and systems integration. Their key capabilities are:
Services
- PCB quickturn prototype fabrication
- SMT and through hole assembly
- Vacuum plasma treatment
- Parylene conformal coating
- Environmental simulation testing
- Fulfillment, shipping and inventory management
- PCB and product design
Technology
- 8 metal layer PCB capabilities
- Line width and space to 6 mil
- Flex and rigid-flex boards
- 90+ lead free assembly lines
- RoHS compliant manufacturing
Markets
- Medical devices
- Aerospace
- Defense
- Industrial
Located in the Northeast tech hub, Plasmatreat provides small and mid-size companies with domestic PCB fabrication through complete product realization.
10. Epec Engineered Technologies
Founded in 1983, Epec is a full-service product realization company based in New Bedford, Massachusetts providing:
PCB Fabrication
- Prototype through mid-volume PCB production
- Rigid and flex circuits
- QuickTurn services in 5 days
- 0.5 mm lines and 0.25mm spaced traces
- 16 layer boards
- Multiple sourcing options
Assembly
- SMT and through-hole component assembly
- Conformal coating, potting, encapsulation
- Clean room assembly
- Integration of cases, cabling, packaging
- Testing capabilities
Focus Industries
- Medical
- Industrial
- Transportation
- Aerospace and defense
Epec enables advanced electronics product development from PCB fabrication to turnkey box build assembly for regulated markets with demanding reliability requirements.
This covers the 10 leading PCB manufacturers in the USA along with their capabilities, technologies and focus industries. Between them, they offer the complete spectrum of PCB fabrication and assembly for prototypes, new product introduction as well as volume production.
PCB Manufacturing Technology Trends
PCB manufacturing is a highly technology driven industry. Fabrication requires advanced processes, equipment and materials engineering innovation. Here are some of the key technology trends shaping the capabilities of domestic PCB manufacturers:
HDI PCBs – Continued advances in high density interconnect PCBs enabling higher component densities and miniaturization. Traces now down to 25 microns.
High layer count – Stackups now routinely exceed 20 layers even for mid-volume applications allowing complex routing.
Embedded passives – Embedding capacitors and resistors inside the PCB provides performance benefits.
Flex and rigid-flex – Demand continues to grow for flexible circuits and multifunction rigid-flex configurations.
RF/microwave materials – New substrate materials to cater to fast-growing wireless and high-frequency applications.
Additive processing – Additive methods for metallization reduce chemicals. Semi-additive also speeds fine line patterning.
Automation – Increased use of automation and smart factory methods for material handling.
Direct imaging – Precision laser direct imaging eliminates artwork films reducing costs.
Advanced finishes – ENIPG, ENEPIG and other finishes provide alternatives to traditional HASL and improve soldering performance.
By adopting these advancing technologies, US manufacturers can stay competitive, meet the most demanding application needs and support advanced electronics innovation.
Benefits of US Based PCB Manufacturing
Procuring printed circuit boards and services from domestic manufacturers in the USA provides several important benefits:
1. Quality and Reliability
American PCB companies adhere to strict quality standards for product consistency and reliability:
- ISO 9001 compliant manufacturing facilities
- IPC standards for fabrication and class specifications
- Rigorous process controls and SPC monitoring
- First pass yield maximization
- Automated optical inspection and electrical testing
- Material traceability and certification
- Attention to counterfeit component avoidance
The focus on quality delivers assurance for medical, automotive, aerospace, defense and other regulated industries where product failures have severe consequences.
2. Advanced Technology Expertise
US companies possess deep expertise in cutting-edge PCB technologies:
- High layer count and HDI
- Flexible and rigid-flex circuits
- RF and high frequency materials
- Miniaturization and advanced packaging
- Quickturn prototyping
- New materials like LCP, ceramic-based
This enables them to produce boards for sophisticated applications and support next-generation product development.
3. Supply Chain Security
Sourcing PCBs domestically eliminates risks associated with offshore supply chains:
- Protection of sensitive intellectual property
- Avoidance of counterfeit risks
- Compliance with defense and regulatory standards
- Material traceability
- Secure transfer of data
- Ability to audit and monitor facilities
For applications requiring high security and product integrity, US PCB manufacturing provides safety.
4. Engineering Collaboration
Language and culture familiarity makes it easier to collaborate during product development:
- Design reviews and DFM analysis
- Material selection assistance
- Stackup development
- Assembly process reviews
- More responsive engineering communication
- Ability to visit facilities
The process runs smoother thanks to greater alignment between PCB engineers and designers.
5. Proximity and Logistics
With manufacturers located nearby, the entire procurement process is simplified:
- Reduce shipping times and costs
- Faster manufacturing feedback loops
- Ability to hold local inventory
- Lower minimum order quantities
- Just-in-time delivery flexibility
- Quick issue resolution
Proximity improves agility while lower logistics overhead reduces total cost.
Factors Driving US PCB Manufacturing Growth
The North American PCB market was estimated to be $5.6 billion in 2021. High mix, low volume applications dominate domestic demand. Here are some factors driving growth in US PCB production:
Increasing Localization Demand
- Government incentives to boost domestic manufacturing capacity.
- Localization mandates for regulated industries like defense, medical and automotive.
- Desire of OEMs to regionalize supply chains and reduce risks.
High Mix Requirements
- Fragmentation of end markets requiring high mix production.
- Lower volume requirements unviable for offshoring.
- Demand for fast prototyping and new product introduction.
Advanced Technology Needs
- Cutting edge and emerging technologies like flex, HDI, RF and EV.
- Specialized technologies require close engineering collaboration.
Agility and Speed
- Startups and small companies needing fast turns and low overhead.
- Accelerated product development cycles.
Quality Mandates
- Stringent standards in high reliability sectors.
- Traceability requirements.
American PCB companies are gearing up with the latest technologies and capabilities to cater to these evolving needs while promoting domestic high-tech manufacturing.
Outlook for American PCB Manufacturing
The future looks bright for American PCB production through the rest of the decade due to the confluence of several macro trends. By adopting Industry 4.0 manufacturing principles and advanced technologies, US manufacturers can thrive in the following areas:
High Mix/Low-Medium Volume – Catering to fragmented markets and customized orders unviable for offshoring.
Quickturn Prototyping – Leveraging automation and interconnectedness for fast NPI.
Advanced Technology – Developing specialized capabilities in emerging products like EVs, renewables and disruptive electronics
