💰 Question: How much does it cost to build a run of 100-500 badges?

The cost of producing electronic badges in medium-sized runs (100-500 units) varies based on several factors. Here's a detailed breakdown:

📊 Cost Components Per Badge

Component	Typical Range (USD)	Notes
PCB Fabrication	$3.30-8.25	Based on 2-4 layer board, standard options
Components (BOM)	$16.50-49.50	Varies with feature set
Assembly (PCBA)	$8.25-24.75	Machine assembly + any hand soldering
Battery	$3.30-13.20	Depends on capacity/type
Case/Housing	$1.65-8.25	If using 3D printed or injection molded
Packaging	$0.83-3.30	Basic protective packaging

🎯 Example Cost Scenarios

Basic LED Badge (100 units)

• Simple MCU + LEDs: ~$33-41.25/unit
• Total run cost: $3,300-4,125

Feature-Rich Badge (100 units)

• Display + WiFi + Sensors: ~$57.75-74.25/unit
• Total run cost: $5,775-7,425

Volume Discounts (500 units)

• Typically 10-20% lower per-unit cost
• Better component pricing
• Lower PCBA setup costs per unit

💡 Cost-Saving Tips

1. Design Choices
2. Use common components
3. Minimize hand-assembly steps

4. Consider panel efficiency

5. Ordering Strategy

6. Order extra boards (10-15%)
7. Buy components with volume pricing

8. Plan for long-lead items early

9. Hidden Costs to Consider

10. Development time
11. Testing equipment
12. Programming jigs
13. Shipping logistics

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