Why HDI PCBs Cost More Than Standard PCBs

4 Key Factors That Drive the Price Difference

Many customers are surprised when they receive a quotation for an HDI (High Density Interconnect) PCB and find that the price is significantly higher than that of a standard PCB.

In reality, this price difference is not arbitrary. HDI PCBs require different materials, more advanced processes, longer production cycles, and stricter quality control. Below, we explain the four main reasons why HDI PCBs typically cost much more than conventional PCBs.

1. Higher Material Requirements

HDI PCBs place much stricter demands on base materials and copper foil compared to standard PCBs.

Thinner and More Specialized Laminates

Standard PCBs commonly use conventional FR-4 laminates with a thickness of around 1.6 mm.
HDI PCBs, however, often require:

Thin FR-4 laminates (typically 0.2–0.4 mm), or
High-speed / high-frequency materials such as PTFE for signal integrity requirements

Thin laminates are more difficult to process, while high-speed materials are significantly more expensive. As a result, material costs alone for HDI PCBs are usually 30–50% higher than for standard PCBs.

Finer Copper Foil

HDI designs feature much finer traces and spaces (often 0.05–0.1 mm), which require high-ductility copper foil, typically 12 μm or thinner.
By comparison, standard PCBs commonly use 25 μm copper foil.

Finer copper foil improves reliability but comes at a cost — it is around 40% more expensive than standard copper foil.

2. More Complex Manufacturing Processes

The core manufacturing processes of HDI PCBs are fundamentally more complex than those of traditional PCBs.

Laser Drilling vs. Mechanical Drilling

Standard PCBs rely on mechanical drilling, which is fast and cost-effective.
HDI PCBs require UV laser drilling to create microvias:

Laser drilling equipment costs 5–10 times more than mechanical drilling machines
Drilling speed is slower
The cost per via can be 8–10 times higher than mechanical drilling

Sequential Lamination

Standard PCBs are typically laminated once, with all layers pressed together in a single cycle.
HDI PCBs use sequential lamination, where layers are built up step by step.

This means:

Multiple lamination cycles (often 3–4 times)
Repeated alignment, drilling, and inspection
Higher labor and equipment usage

Each additional lamination step significantly increases manufacturing cost.

3. Lower Production Efficiency and Longer Lead Time

HDI PCBs require more process steps and tighter controls, which directly affects production efficiency.

Standard PCBs:
- 15–20 process steps
- Typical lead time: 7–10 days
HDI PCBs:
- 25–30 process steps
- Typical lead time: 15–20 days

In addition, HDI PCBs demand extremely tight tolerances (often ±0.02 mm). Frequent inspections are required throughout production, increasing downtime and reducing throughput.

Lower efficiency means fewer boards can be produced within the same time frame — increasing the cost per unit.

4. Stricter Inspection and Lower Yield

Due to their high density and precision requirements, HDI PCBs are more sensitive to manufacturing variations.

Yield rates for HDI PCBs are often 10–20% lower than for standard PCBs
Any defects can lead to scrapped panels, and those losses must be absorbed into the cost of acceptable boards

Inspection costs are also higher:

HDI PCBs require high-resolution AOI systems
Advanced AOI equipment can cost 3–5 times more than standard systems
Inspection costs per board increase accordingly

Conclusion: HDI PCB Cost Is a Result of Total Manufacturing Complexity

HDI PCBs are more expensive not because of a single factor, but because materials, processes, production time, and yield risks all increase simultaneously.

In many projects, early design optimization can significantly reduce costs:

Avoid HDI structures when they are not strictly necessary
Use lower-order blind/buried vias whenever possible
Balance electrical performance with manufacturability (DFM)

Working closely with an experienced PCB manufacturer during the design stage is often the most effective way to control HDI PCB costs.

About Us

We are a China-based PCB and PCBA manufacturer providing one-stop PCB manufacturing, assembly, and sourcing services for global electronics companies. With extensive experience in HDI and multilayer PCB production, we help customers optimize designs for performance, manufacturability, and cost.

If you would like assistance reviewing your PCB design or reducing manufacturing cost, feel free to contact us.