It isn't wizardry to get circuit boards for $2 - it's smart panelization! Instead of purchasing one small PCB, you can panelize multiple copies of the same design or, in some cases, different designs onto a single large panel, maximizing the value of the fixed price levels each supplier offers. Most manufacturers charge by panel size, not quantity of PCBs, so excess space on a panel is simply wasted money.

Smart panelisation by splitting a bigger PCB board

The good news is that PCB design tools provide on-board features for easy panelization, so you can just copy the layout of the PCB, add tab breaks for separation, and optimize the layout to maximize all available space on the panel. You can use v-cuts or mouse bites to easily separate each PCB after they have been fabricated.

The key to this is thinking of the wasted PCB space as if it were rent; you pay for it already, so you might as well use every millimeter.

The Secret to $2 PCBs: Maximizing Panelization on a Budget