Small Batch PCB Production with LPKF ProtoLaser – 234 Boards in 2.5 Hours | LPKF
Small Batch PCB Production with the LPKF ProtoLaser: 234 Boards in 2 Hours 18 Minutes
Prototype done, function confirmed – now what? For many engineers, this is where the next problem starts: you don't need 1 board, but you also don't need 10,000. You need 50, 200, or 500. Fast, without outsourcing, without waiting. A recent hands-on example with the LPKF ProtoLaser shows exactly what's possible: 234 finished PCBs, fully structured, drilled, and cut – in 2 hours and 18 minutes.
The Bottleneck Between Prototype and Small Batch – and How Step & Repeat Solves It
PCB prototyping systems are often seen as single-board machines. One design, one run, one board. That's true for the development phase. But once you need 200 identical boards, most engineers go straight to external PCB manufacturers – with lead times of several days or weeks.
The Step & Repeat function in LPKF's CircuitPro software addresses this directly. A single layout is automatically arranged into a panel array – in this case an 18 x 13 grid, giving 234 identical PCBs on one base material. The ProtoLaser then handles structuring, drilling, and contour cutting in a single run.
In-house Small Batch Production – Three Things You Need
To make this work, three things are required:
1. A ProtoLaser system with a working area large enough for the planned panel size.
2. CircuitPro with the Step & Repeat function enabled for automatic panel layout.
3. Base material in panel size – standard FR4 works in most cases.
35.4 Seconds per PCB – What That Number Actually Means
234 boards in 138 minutes: that's 35.4 seconds per piece. For comparison: external PCB manufacturers typically require several business days for a small batch of this size – plus shipping time and minimum order quantities.
The key difference isn't just speed. It's everything that disappears with in-house production: no outsourcing, no external data transfer, no minimum order quantity. If you need 50 boards, you make 50 boards.
Laser vs. Milling: Why the ProtoLaser Is the Right Choice for Small Batches
LPKF offers PCB structuring in two technology paths: mechanical (ProtoMat) and laser-based (ProtoLaser). For single prototypes, both approaches deliver comparable results. For small batch production, the ProtoLaser has clear advantages:
No tool wear across multiple runs.
Consistent trace widths even when running the same job repeatedly.
Higher precision for fine structures – especially relevant for RF designs or tight pad spacings.
Silent operation, no mechanical stress on the base material.
Where In-house Small Batch PCB Production Makes Sense
The 234-board example illustrates what's needed across several practical scenarios:
Research and Academia
Universities and research institutes frequently need identical boards in larger quantities for test series. With the ProtoLaser and Step & Repeat, these batches can be produced within a single lab day – without sending designs to an external supplier.
Startup and Scale-up Phases in Electronics Development
Between a working prototype and a production-ready lot size, many development teams face a costly and time-consuming gap. In-house small batch production closes that gap: iterate the product, test functionality, make decisions – without external dependencies.
Pilot Runs Before Production Launch
Before a design enters external mass production, quality samples, functional prototypes, and validation boards need to be produced. In-house production is faster, more cost-effective, and gives direct control over every step in the process.
See the Workflow in Action – the Video
What the complete run looks like in practice – from panel layout in CircuitPro to the finished panel with 234 cut-out boards – is shown in LPKF's latest video:
Conclusion: Small Batch Is No Longer a Compromise
Fast and precise. No external supplier. What sounds exceptional is repeatable standard practice with the LPKF ProtoLaser and CircuitPro Step & Repeat. For development labs, research teams, and anyone who can't afford to lose a month between prototype and small series.
Do you have any questions?
Our experts will help you determine which technology best suits your specific requirements, whether you're developing complex RF circuits, flexible substrates, or standard PCBs for embedded applications. Contact us via our form or subscribe to our newsletter for updates.
