PCB Design Tools
PANELIZATION CALCULATOR
Calculate optimal PCB panel layout for manufacturing. Maximize board count and material utilization with V-score or tab routing options.
Calculate optimal PCB panel layout for manufacturing. Maximize board count and material utilization with V-score or tab routing options. Enter your board and panel dimensions below -- results update in real time.
Board Dimensions
Panel Dimensions
Separation Method
Panelization Results
Total Boards Per Panel
4 × 2 array
Panel Utilization
Usable Width
240.0 mm
Usable Height
190.0 mm
Recommendation: Acceptable for most applications.
Panel Preview
PCB Panelization Calculator Results
Generated by calpak-usa.com/Resources/PCB-Panelization-Calculator
| Board Size | 50 x 80 mm |
| Panel Size | 250 x 200 mm |
| Rail Width | 5 mm |
| Separation | V-Score (0.5 mm) |
| Boards Per Panel | 8 (4 x 2) |
| Usable Area | 240.0 x 190.0 mm |
| Utilization | 64.0% |
For reference only -- always verify panel layout with your PCB fabricator.
Common Panel Sizes
| Panel Size | Area | Typical Use |
|---|---|---|
| 100x100mm | 100 cm² | Small prototypes |
| 150x100mm | 150 cm² | Prototypes |
| 200x150mm | 300 cm² | Small production |
| 250x200mm | 500 cm² | Medium production |
| 300x250mm | 750 cm² | Large production |
| 457x305mm | 1394 cm² | High volume (18"x12") |
*Available sizes vary by manufacturer. Check with your PCB supplier for their standard panel sizes.
Board Separation Methods
V-Score (V-Groove)
Shallow V-shaped groove cut into both sides of the PCB, typically 1/3 depth each side:
- ✓ Clean, straight break lines
- ✓ Minimal gap between boards (0.2-0.5mm)
- ✓ Lower cost than routing
- ! Only for straight lines, full panel width
Tab Routing
Boards connected by small breakaway tabs with routed perforations:
- ✓ Works with irregular board shapes
- ✓ Mouse bites for easy separation
- ✓ Better for fragile components near edges
- ! Larger gap (2-3mm), rough edge at tabs
Panelization Best Practices
Rail Width
Use 5-10mm rails for SMT assembly. Include fiducial marks and tooling holes in rails for pick-and-place alignment.
Rotation
Try both orientations -- rotating boards 90° can sometimes fit more boards or improve utilization significantly.
Keep-Outs
Maintain clearance from V-score lines for components and traces. Typically 0.5-1mm minimum from groove edge.
Panel Utilization Guidelines
Excellent
Optimal layout, cost-effective production
Good
Acceptable for most applications
Moderate
Consider different panel size or rotation
Poor
Significant waste, review board and panel dimensions
Manufacturing Considerations
- Mixed arrays: Different board designs can be combined on one panel if they share the same layer stackup and specifications.
- Assembly rails: For automated assembly, include handling rails with fiducials even if they reduce utilization.
- Test points: Consider adding test coupons or impedance test strips in waste areas of the panel.
- Depaneling stress: Component placement near break lines should account for mechanical stress during separation.
Calpak USA's engineering team can optimize your panel design for maximum yield and manufacturability. Contact us for a panelization review.
LET'S BUILD // TOGETHER
Ready to Start Your
Next Project?
Calpak USA provides full-service PCB fabrication and panel design from our Hawthorne, CA facility.
Request a Quote