Inquire: Call 0086-755-23203480, or reach out via the form below/your sales contact to discuss our design, manufacturing, and assembly capabilities.
Quote: Email your PCB files to Sales@pcbsync.com (Preferred for large files) or submit online. We will contact you promptly. Please ensure your email is correct.
Notes: For PCB fabrication, we require PCB design file in Gerber RS-274X format (most preferred), *.PCB/DDB (Protel, inform your program version) format or *.BRD (Eagle) format. For PCB assembly, we require PCB design file in above mentioned format, drilling file and BOM. Click to download BOM template To avoid file missing, please include all files into one folder and compress it into .zip or .rar format.
IPC-2578 Guide: Exchanging Bills of Material with Contract Manufacturers
Sending a BOM to your contract manufacturer shouldn’t feel like throwing data into a black hole. Yet for many electronics companies, that’s exactly what happens. You export a spreadsheet from your PLM, email it over, and then spend the next two weeks answering questions about part numbers, approved sources, and revision history. The IPC-2578 standard exists precisely to solve this problem.
After years of managing BOM transfers between design teams and CMs, I can tell you that standardized data exchange isn’t just about convenience—it’s about reducing the errors that cost real money on the production line.
IPC-2578 is the sectional standard within the IPC-2570 series that defines how to exchange Bills of Material (BOM), Approved Manufacturer Lists (AML), Approved Supplier Lists (ASL), and engineering change data between supply chain partners. Published by IPC (Association Connecting Electronics Industries) and adopted by ANSI in November 2001, it provides an XML-based format for communicating design configuration data.
In practical terms, IPC-2578 tells you exactly how to structure your BOM data so that your contract manufacturer’s systems can read it without manual intervention. It covers not just the part list itself, but also the approved sources for each component and the change history that got you to the current revision.
What Data Does IPC-2578 Cover?
The standard addresses several critical data types that every electronics manufacturer needs to exchange:
Data Type
Description
Business Purpose
Bills of Material (BOM)
Multi-level product structure with quantities and reference designators
Manufacturing planning, procurement
Approved Manufacturer Lists (AML)
Qualified component manufacturers for each line item
Source control, quality assurance
Approved Supplier Lists (ASL)
Authorized distributors and vendors
Procurement authorization
Component Data
Electrical, mechanical, and package specifications
Engineering reference
Engineering Change Orders (ECO)
Change history with revision tracking
Configuration management
Manufacturing Change Orders (MCO)
Production-related changes
Process control
The IPC-2570 Series: Where IPC-2578 Fits
IPC-2578 doesn’t work alone. It’s part of the Product Data eXchange (PDX) family of standards that together enable complete supply chain communication.
IPC-2570 Series Overview
Standard
Focus Area
Key Data Elements
IPC-2571
Generic PDX requirements
Package structure, contacts, attachments
IPC-2576
As-built product data
Serial numbers, lot codes, production records
IPC-2578
Design configuration data
BOM, AML, ASL, ECO, component specs
IPC-2577
Quality assessment data
Inspection results, test data (proposed)
Think of IPC-2571 as the container format that holds everything together. IPC-2578 provides the “design intent” data—what you want to build—while IPC-2576 handles the “manufacturing reality” data—what actually got built. When you send a PDX package to your CM, you’re typically including both IPC-2578 data (the BOM and sourcing instructions) and expecting IPC-2576 data back (the as-built records).
Core XML Elements in IPC-2578
Understanding the XML structure helps when you’re troubleshooting integration issues or evaluating PLM systems. Here are the key elements defined by IPC-2578:
The beauty of IPC-2578 is how it connects related data. An Item (your internal part number) can have a BillOfMaterial (its components), an ApprovedManufacturerList (who can make each component), and be referenced by Change elements (how it evolved over time). This interconnected structure means your CM gets context, not just a flat list of parts.
For example, when your CM looks at a capacitor on your BOM, they can immediately see which manufacturer part numbers are approved, which suppliers they can purchase from, and what changed in the last revision. That context eliminates questions and prevents errors.
Why IPC-2578 Matters for Contract Manufacturing
If you’re still exchanging BOMs via Excel spreadsheets, you’re accepting risks that standardized exchange eliminates.
The Real Cost of Non-Standard BOM Exchange
Every time you manually transfer BOM data, you introduce potential errors:
Error Type
Consequence
IPC-2578 Solution
Transcription errors
Wrong parts ordered
Machine-readable XML eliminates retyping
Missing AML data
Unapproved substitutions
AML embedded in same package
Revision confusion
Builds to wrong revision
Change history included
Reference designator mismatches
Assembly errors
RefDes data structurally linked to components
Incomplete component data
Procurement delays
Component specs embedded per standard
Business Benefits of IPC-2578 Adoption
Organizations implementing IPC-2578 typically see improvements in several areas:
Reduced NPI Time: New product introduction cycles shorten when CMs can import BOM data directly into their MES and ERP systems without manual data entry. What once took days of back-and-forth communication can happen in hours.
Fewer Engineering Questions: When AML data travels with the BOM, procurement doesn’t need to email you asking which manufacturers are approved for each component. All sourcing decisions are documented and transferred automatically.
Better Change Control: ECO history in the PDX package means everyone works from the same revision understanding. No more builds to obsolete BOMs because someone was working from an outdated spreadsheet.
Audit Trail: The structured format creates a documented record of what design data was transferred and when. For regulated industries, this traceability is essential for compliance.
Supplier Flexibility: When supply chain disruptions occur, having structured AML data makes it easier to qualify and switch to alternative sources without recreating documentation from scratch.
How BOM Exchange Actually Works with IPC-2578
Let me walk through a typical exchange scenario between an OEM and contract manufacturer.
Step 1: Design Release
Your design team finalizes a PCBA design in your CAD tool. The schematic and layout are complete, and the BOM has been reviewed. At this point, your PLM system holds the engineering BOM (EBOM) with all component data and approved sources.
Step 2: PDX Package Generation
Your PLM exports a PDX package conforming to IPC-2571/2578. This compressed file contains:
The pdx.xml file contains your complete product definition in XML format, with Items, BillOfMaterial structures, ApprovedManufacturerLists, and any related Changes.
Step 3: CM Import
Your contract manufacturer’s system reads the PDX package and imports the data into their MES/ERP. Because the format is standardized, their system knows exactly where to find part numbers, quantities, reference designators, and approved sources.
Step 4: Manufacturing
Production proceeds using the imported data. As units are built, the CM’s traceability system captures actual component lot codes, serial numbers, and process data.
Step 5: As-Built Data Return
The CM exports as-built records in IPC-2576 format, often packaged with the original IPC-2578 design data. You now have a complete record linking design intent to manufacturing reality.
Approved Manufacturer Lists in IPC-2578
One of IPC-2578’s most valuable features is structured AML support. In electronics manufacturing, controlling component sources is essential for quality, reliability, and supply chain resilience.
Why AML Management Matters
Industry
AML Requirement Level
Key Drivers
Aerospace & Defense
Mandatory
AS9100, DFARS, traceability requirements
Medical Devices
Mandatory
FDA regulations, ISO 13485, patient safety
Automotive
Required
IATF 16949, warranty cost reduction
Industrial
Recommended
Quality consistency, supply security
Consumer Electronics
Variable
Cost optimization, availability
AML Structure in IPC-2578
The ApprovedManufacturerList element contains ApprovedManufacturerListItem entries, each referencing a ManufacturerPart. This creates a clear hierarchy:
Your Part Number (Item) → Approved Sources (AML) → Specific Manufacturer Parts
When your CM receives this data, their purchasing team knows exactly which manufacturer part numbers they can procure without coming back to you for approval. This eliminates one of the biggest sources of delay in the build process.
The Change element in IPC-2578 captures ECO and MCO information, providing revision history within the PDX package.
Change Data Elements
Attribute
Purpose
Example Values
changeType
Type of change
ECO, MCO, Deviation
changeStatus
Current status
Open, Approved, Implemented
changeReason
Why the change was made
Cost reduction, reliability improvement
requestReason
Original request driver
Customer request, field failure
effectivity
When change takes effect
Serial number range, date
Having change history travel with the BOM means your CM understands not just what the current design is, but how it evolved. This context helps when troubleshooting issues or managing mixed-revision inventory.
Implementing IPC-2578: Practical Considerations
If you’re evaluating IPC-2578 implementation, here’s what to consider:
PLM System Support
Most enterprise PLM systems support PDX export:
PLM System
PDX Support
Notes
Oracle Agile
Native
Original PDX implementation reference
Arena Solutions
Native
Includes free PDX viewer (Arena Exchange)
PDXpert
Native
Focused on PDX compliance
PTC Windchill
Via configuration
May require customization
Siemens Teamcenter
Via integration
Typically needs middleware
Contract Manufacturer Readiness
Before assuming your CM can handle PDX files, verify their capabilities:
Questions to Ask Your CM:
Can you import IPC-2571/2578 PDX packages directly?
Which PLM/MES systems do you use for BOM import?
Do you have a PDX viewer for manual review?
Can you export IPC-2576 as-built data?
Data Quality Requirements
IPC-2578 can only exchange data that exists. Before implementing, ensure your systems capture:
Complete BOM structures with quantities and reference designators
Approved manufacturer lists for all purchased components
IPC-2576 — As-built product data exchange (manufacturing traceability)
IPC-2581 — Modern XML schema for PCB manufacturing data
IPC-1782 — Manufacturing and supply chain traceability requirements
Common Challenges and Solutions
Challenge: Legacy System Integration
Many organizations run ERP or MES systems that predate PDX standards. Extracting or importing data in XML format requires custom development.
Solution: Consider middleware solutions or integration platforms that can transform PDX data to/from your legacy formats. Some organizations use scheduled batch processes that convert PDX to CSV for import into older systems.
Challenge: Incomplete AML Data
Your PLM may not have manufacturer part numbers for every component, especially for commodities like resistors and capacitors.
Solution: Invest in component engineering to build out your AML before attempting IPC-2578 implementation. The standard can only transfer data that exists in your source system.
Challenge: CM Capability Variations
Not all contract manufacturers have the same PDX capabilities. What works with one CM may not work with another.
Solution: Include PDX capability requirements in your CM qualification process. Standardize on CMs who can support your data exchange requirements, or maintain multiple export formats during transition.
Frequently Asked Questions About IPC-2578
What is the difference between IPC-2578 and IPC-2576?
IPC-2578 handles design configuration data—the BOM, approved sources, and engineering changes that define what you intend to build. IPC-2576 handles as-built data—the serial numbers, lot codes, and production records that document what was actually manufactured. Think of IPC-2578 as “design intent” and IPC-2576 as “manufacturing reality.” Both are typically needed for complete supply chain communication.
Can IPC-2578 replace Excel BOM exchanges?
Yes, that’s exactly what it’s designed to do. Instead of emailing spreadsheets that require manual import and interpretation, IPC-2578 provides a machine-readable format that your CM’s systems can import directly. The structured XML format eliminates transcription errors and includes contextual data (AML, changes) that spreadsheets typically lack.
What PLM systems support IPC-2578 PDX export?
Most enterprise PLM systems support PDX export either natively or through configuration. Oracle Agile, Arena Solutions, and PDXpert have native support. PTC Windchill and Siemens Teamcenter typically require configuration or middleware. Check with your PLM vendor for specific capabilities and any required add-ons.
Is IPC-2578 required for electronics manufacturing?
IPC-2578 is not universally mandated, but it’s increasingly expected by sophisticated contract manufacturers, especially those serving aerospace, defense, automotive, and medical device markets. If your CM requests “PDX format” for BOM exchange, they’re asking for IPC-2571/2578 compliant data.
How does IPC-2578 handle multi-level BOMs?
IPC-2578 supports multi-level (indented) BOMs through nested BillOfMaterial and BillOfMaterialItem elements. Each subassembly is defined as an Item with its own BillOfMaterial, creating a hierarchical structure that represents your complete product. The standard handles parent-child relationships, allowing your CM to see the full assembly breakdown.
Moving Forward with IPC-2578
The electronics industry continues to demand better data exchange between design and manufacturing. While IPC-2578 dates from 2001, the fundamental problem it solves—standardized BOM communication—remains highly relevant. Newer standards like IPC-2581 address manufacturing data with modern XML schemas, but IPC-2578 remains the primary standard for BOM and sourcing data exchange.
If you’re currently exchanging BOMs via spreadsheets and PDFs, moving to IPC-2578 will reduce errors, accelerate NPI cycles, and improve collaboration with your contract manufacturers. The investment in proper data structure pays dividends every time you release a new product or implement an engineering change.
Start by auditing your current BOM data quality, verifying your PLM’s PDX capabilities, and discussing requirements with your contract manufacturers. The path to standardized exchange is straightforward once you understand what IPC-2578 offers.
The bottom line is this: in modern electronics manufacturing, data quality and data exchange capabilities are competitive advantages. Companies that master standardized BOM exchange spend less time on administrative coordination and more time on engineering innovation. IPC-2578 provides the framework to make that happen.
Inquire: Call 0086-755-23203480, or reach out via the form below/your sales contact to discuss our design, manufacturing, and assembly capabilities.
Quote: Email your PCB files to Sales@pcbsync.com (Preferred for large files) or submit online. We will contact you promptly. Please ensure your email is correct.
Notes: For PCB fabrication, we require PCB design file in Gerber RS-274X format (most preferred), *.PCB/DDB (Protel, inform your program version) format or *.BRD (Eagle) format. For PCB assembly, we require PCB design file in above mentioned format, drilling file and BOM. Click to download BOM template To avoid file missing, please include all files into one folder and compress it into .zip or .rar format.
