Featured Snippet: Cost per Hole = (Bit Cost / Hit Count) + (Entry + Backup Cost) / Holes per Panel
Free PCB drill cost calculator. Model cost per hole and per panel from bit cost, hit count, entry and backup board cost, and holes per panel.
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Model drilling cost per hole and per panel.
| Bit cost per hole | -- |
| Board cost per hole | -- |
| Cost per 1000 holes | -- |
| Cost per panel | -- |
Planning model - replace with your real bit and board quotes; better boards that raise hit count often lower total cost.
Drilling cost is the sum of bit consumption and board material per panel. Knowing cost per hole lets process engineers justify a better entry/backup board that lifts hit count and actually lowers unit cost. This tool models cost per hole and per 1000 holes from your inputs.
Bit cost per hole falls as hit count rises. A lubricant aluminum entry sheet or UV melamine backup board that adds 15-25% hits can offset its own price and cut total unit cost - while also improving burr and hole wall roughness. Model both scenarios in the tool before choosing. See our backup board range and lubricant aluminum pages for specs.
| Material | Feed Stability | Burr Control | Tool Life |
|---|---|---|---|
| UV Melamine backup board | ★★★★★ | ★★★★★ | ★★★★ |
| Phenolic backup board | ★★★★ | ★★★★ | ★★★ |
| Aluminum entry sheet | ★★★★★ | ★★★★★ | ★★★★ |
Stable feed rate and clean exits are what let you push hit count without micro-drill breakage. Pair the right board with the parameters from this tool — see our backup board range and aluminum entry boards.
| Material | RPM | Chip load | Feed (m/min) | Entry | Backup |
|---|---|---|---|---|---|
| FR4 (standard multilayer) | 90,000 | 0.012 | 2.16 | Aluminum entry sheet | HDF backup board |
| HDI / micro-via | 110,000 | 0.008 | 1.76 | Lubricant aluminum | UV melamine 880 backup board |
| Rogers (high-frequency) | 80,000 | 0.010 | 1.60 | Aluminum entry sheet | Phenolic backup board |
| PTFE / Teflon | 60,000 | 0.008 | 0.96 | Aluminum entry sheet | Phenolic backup board |
| IC substrate (ABF) | 120,000 | 0.006 | 1.44 | Lubricant aluminum | UV melamine 950 backup board |
| Ceramic PCB | 50,000 | 0.008 | 0.80 | Aluminum entry sheet | Phenolic backup board |
| Aluminum PCB (IMS) | 40,000 | 0.010 | 0.80 | Aluminum entry sheet | Phenolic backup board |
| Copper-core PCB | 30,000 | 0.010 | 0.60 | Aluminum entry sheet | Phenolic backup board |
Figures are qualified starting points cross-checked with published fabrication guidance and supplier benchmarks — validate on your own panels.
Cost per 1,000 holes (0.20 mm drill)
Representative field benchmarks for a 0.20 mm drill on standard FR4; actual results vary with stackup, machine and consumables — validate on your own panels.
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What is cost per hole? Cost per hole = bit cost / hit count + board material cost / holes per panel.
How do I lower drilling cost? Raise hit count with better boards, or lower bit/board unit cost - model both in the calculator.
What is hit count? Holes a bit drills before resharpening; higher hit count lowers bit cost per hole.
Does a lubricant entry sheet save money? Often yes - the hit-count gain can offset its price and cut total unit cost.
What is a backup board cost driver? Material grade (UV melamine vs phenolic) and thickness set per-panel board cost.
What is the bit cost per hole? Bit price divided by hit count; the dominant cost on hole-rich HDI panels.
What is tool life? Total holes per bit before resharpening; the practical mirror of hit count.
What is drill breakage cost? Wasted bit plus scrapped panel; good support reduces both.
What is burr and why care? Exit burr adds a cleaning step; clean exits from good boards save rework.
What is hole wall roughness cost? Rough holes may need extra desmear/plating care, adding cost.
What is a good hit count for 0.20 mm? About 4,000-4,500 hits on FR4 with good support.
What is the cost of a drill bit? Micro bits are priced per piece and resharpened several times.
What is stack height effect on cost? Taller stacks lower hit count, raising bit cost per hole.
What is via reliability vs cost? Cheap boards that hurt holes can cost more in field failures; balance both.
What is chip evacuation role? Good evacuation extends tool life, lowering cost per hole.
What is the difference between mechanical and laser cost? Laser micro-vias avoid bits for tiny vias but need laser capex; compare by density.
The fundamental relationship — Feed (mm/min) = RPM × chip load × flutes — governs heat generation, burr formation, and tool wear. For micro-drills below 0.2 mm, keep chip load between 0.005–0.012 mm/tooth to avoid drill breakage. Validate on your stack with a sample before committing to production.
Proto-Electronics — PCB drilling process ↗
Stack height and aspect ratio (hole depth ÷ diameter) interact directly with feed parameters. High aspect ratio holes (> 10:1) require reduced feed to maintain chip evacuation and avoid resin smear. Pairing a lubricated entry board with a UV melamine backup board supports higher stacks without quality degradation.
NCAB Group — HDI / microvia design ↗
Tool life is maximised when feed rate keeps the cutting edge loaded (not rubbing). A stable feed of 6–12 mm/min for 0.2 mm drills on FR4 typically yields 3,000–4,000 hits per bit. Worn bits increase burr height and hole wall roughness — monitor both as end-of-life indicators.
IPC — rigid PCB standards (IPC-6012) ↗
The entry board material directly affects parameter stability. Standard aluminum entry sheets provide consistent centering for most builds; lubricated aluminum entry sheets reduce drill wander on micro-vias below 0.15 mm and enable higher feed rates by lowering frictional heat.
YUESHAN — What is an entry board
The backup board absorbs exit energy and controls burr. UV melamine boards (880/950 grades) offer the best surface hardness for HDI and fine-pitch work; HDF is cost-effective for standard FR4; phenolic suits back-drilling and rigid-flex applications.
YUESHAN — What is a backup board
The total cost per hole includes drill bit cost, entry/backup board cost, machine time, and scrap. Optimising parameters to increase hit count by even 20% often has a higher ROI than reducing consumable cost per sheet. Use the tools on this site to model the trade-offs.
Process and CAM engineers use these numbers across demanding builds:
The right entry and backup board is what actually lets you hold a stable feed rate without breakage. Explore the product lines:
HDF, UV melamine and phenolic backup boards for stable exits and burr control.
Product Page →Plain and coated aluminum entry boards, including lubricated grades for micro-holes.
Product Page →Self-lubricating entry sheets that cool and center the bit on HDI / micro-via drilling.
Product Page →Coated back-drill entry sheets built for controlled-depth second-pass accuracy.
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