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.
How do you objectively compare PCB fabricators when every manufacturer claims world-class quality? Asking for capability statements gives you marketing material. Requesting sample builds tells you what they can do once, not consistently. The electronics industry needed a standardized, data-driven approach to benchmark PCB manufacturing capability. That’s exactly what IPC-9151 delivers.
IPC-9151, the Process Capability, Quality, and Relative Reliability (PCQR2) Benchmark Test Standard and Database, provides a standardized methodology for evaluating and comparing printed circuit board fabricator capabilities. Through defined test panel designs, statistical analysis, and peer comparison databases, IPC-9151 transforms subjective supplier qualification into objective, measurable benchmarking. This guide explains how the PCQR2 program works and how to use it effectively for PCB supplier evaluation.
IPC-9151 is the IPC standard that defines the PCQR2 (Process Capability, Quality, and Relative Reliability) benchmark testing program for printed circuit board manufacturers. Rather than relying on self-reported capabilities or one-off sample builds, IPC-9151 establishes standardized test panel designs, manufacturing protocols, testing procedures, and data analysis methods that enable objective comparison of PCB fabricators.
IPC-9151 Standard Overview
Attribute
Details
Full title
Printed Board Process Capability, Quality, and Relative Reliability (PCQR2) Benchmark Test Standard and Database
Current revision
IPC-9151D (May 2012)
Previous revisions
IPC-9151C (2010), B (2007), A (2003), Original (2002)
The standard was developed in response to a clear industry need identified in The National Technology Roadmap for Electronic Interconnections, which stated that companies must identify supplier capabilities and ensure manufacturing consistency with customer requirements.
IPC-9151 Revision History
Revision
Date
Key Changes
IPC-9151
June 2002
Original release, established PCQR2 framework
IPC-9151A
May 2003
Expanded test structures
IPC-9151B
February 2007
Added assembly simulation profiles
IPC-9151C
May 2010
Updated test methods
IPC-9151D
May 2012
Enhanced microvia structures, HDI patterns
Understanding the PCQR2 Program
The PCQR2 program provides an industry-standard approach to benchmarking PCB manufacturing capabilities. Rather than each OEM developing proprietary qualification panels and testing methods, PCQR2 offers standardized designs that enable direct comparison across the industry.
Validated manufacturing capabilities for design rules
Quality engineers
Standardized assessment methodology
Supply chain managers
Data-driven sourcing decisions
The Five Capability Areas Tested in IPC-9151
The PCQR2 program evaluates PCB fabricator capabilities across five critical manufacturing areas. These areas represent the key process attributes that determine whether a fabricator can reliably produce boards to specification.
Capability Area Overview
Capability Area
What’s Measured
Why It Matters
Conductors and spaces
Trace width, spacing capability
Determines routing density limits
Via formation and registration
Hole quality, layer alignment
Affects interconnect reliability
Soldermask registration
Mask-to-feature alignment
Impacts assembly yield
Controlled-depth drilling
Depth accuracy, overshoot
Critical for blind vias, backdrilling
Controlled impedance
Impedance accuracy, consistency
Essential for high-speed designs
Conductor and Space Capability Testing
Test Parameter
Description
Minimum trace width
Smallest reliable conductor
Minimum spacing
Closest reliable gap between conductors
Trace width variation
Consistency across panel
Etch uniformity
Center-to-edge variation
Fine-line capability
Sub-3-mil trace/space performance
Via Formation and Registration Testing
Test Parameter
Description
Hole position accuracy
Drill-to-artwork registration
Layer-to-layer registration
Internal layer alignment
Aspect ratio capability
Hole depth to diameter ratio
Microvia formation
Laser-drilled via quality
Blind/buried via reliability
Sequential lamination accuracy
Soldermask Registration Testing
Test Parameter
Description
Mask-to-pad alignment
Registration accuracy
Dam integrity
Mask between fine-pitch pads
Coverage consistency
Thickness uniformity
Solder dam width
Minimum reliable dam
Controlled-Depth Drilling Testing
Test Parameter
Description
Depth accuracy
Target vs actual depth
Depth consistency
Variation across panel
Overshoot control
Penetration beyond target
Stub length
Remaining copper after backdrill
Controlled Impedance Testing
Test Parameter
Description
Impedance accuracy
Target vs measured impedance
Impedance variation
Consistency across panel/lot
Differential pair matching
Pair-to-pair consistency
TDR correlation
Measurement repeatability
PCQR2 Test Panel Designs
Conductor Analysis Technologies developed a family of standardized test panel designs for the PCQR2 program. These panels incorporate progressively challenging features to evaluate fabricator capabilities across complexity levels.
Available Panel Layer Counts
Layer Count
Typical Applications
Complexity Level
8-layer
Standard multilayer
Entry level
10-layer
Industrial controls
Moderate
12-layer
Telecom equipment
Moderate-high
18-layer
High-performance computing
High
24-layer
Networking, servers
Very high
36-layer
Backplanes
Ultra-high
Test Panel Features
Feature Category
Included Structures
Trace/space
Scaled patterns from 2 mil to production rules
PTH holes
Various aspect ratios (up to 14:1 or higher)
Blind vias
Laser-drilled microvias, stacked/staggered
Buried vias
Internal interconnects
Registration targets
Layer alignment verification
Impedance coupons
Controlled impedance structures
Daisy chains
Reliability test structures
2017 Pattern Updates
In 2017, CAT released updated PCQR2 test patterns developed with guidance from the IPC D-36 subcommittee. These patterns provide enhanced evaluation capabilities.
For fabricators seeking to demonstrate their capabilities through the PCQR2 program, IPC-9151 defines a clear participation process.
Participation Requirements
Requirement
Details
Panel manufacturing
Three builds of five panels each
Build timing
Spread over several weeks
Normal production
Panels manufactured using standard processes
Documentation
Fabrication profile and process information
Submission
Complete panels sent to CAT
Submission Process
Step
Action
1
Contact CAT to initiate participation
2
Select appropriate panel complexity level
3
Receive panel artwork and specifications
4
Manufacture panels per standard production processes
5
Complete fabricator profile questionnaire
6
Ship panels to CAT for testing
7
Receive individual capability report
8
Obtain peer comparison data (for subscribers)
What Fabricators Receive
Deliverable
Description
Individual report
Detailed statistical data on submission
Capability metrics
Quantified process capabilities
Peer comparison
Ranking among similar submissions
Trend analysis
Performance over time (multiple submissions)
Improvement guidance
Areas for process enhancement
Using IPC-9151 for PCB Supplier Qualification
For OEMs and contract manufacturers, the PCQR2 database provides a powerful tool for supplier qualification and sourcing decisions.
Traditional vs PCQR2-Based Qualification
Aspect
Traditional Approach
PCQR2 Approach
Test design
Customer-specific
Industry-standard
Comparison basis
Subjective
Statistical
Qualification cost
High (unique per customer)
Shared across industry
Data availability
Limited
Database of peers
Objectivity
Variable
Standardized
Supplier burden
Multiple unique qualifications
Single industry qualification
Implementing PCQR2 in Sourcing
Step
Action
1
Define required capability levels for product
2
Request PCQR2 data from potential suppliers
3
Compare supplier capabilities to requirements
4
Evaluate peer comparison rankings
5
Incorporate PCQR2 data into RFQ criteria
6
Use capability data for design rule validation
Sourcing Model Integration
Leading OEMs integrate PCQR2 data directly into their sourcing models. Rather than sending RFQs to all suppliers, the capability database guides which suppliers receive quotes for specific board complexity levels.
Complexity Level
Supplier Qualification Criteria
Standard
Any qualified supplier
Moderate
PCQR2 Tier 2 or above
High
PCQR2 Tier 1 in relevant capability
Critical
Top-tier PCQR2 ranking required
PCQR2 Database and Reporting
The PCQR2 database serves as the central repository for fabricator capability data, enabling industry-wide benchmarking and comparison.
Database Components
Component
Description
Fabricator profiles
Company and facility information
Test data
Raw measurements from panel testing
Statistical analysis
Capability calculations and metrics
Peer rankings
Comparative performance data
Historical data
Trend information for repeat submissions
Report Types
Report Type
Content
Audience
Individual fabricator
Detailed capability statistics
Submitting fabricator
Peer comparison
Ranking among participants
Database subscribers
Capability summary
High-level capability overview
OEM qualification
Trend report
Performance over multiple submissions
Continuous improvement
Major Program Subscribers
The PCQR2 program attracted participation from leading electronics companies seeking objective supplier data.
Industry Segment
Example Subscribers
Aerospace/Defense
Honeywell International Inc.
Telecommunications
Major networking OEMs
Industrial
Leading control system manufacturers
Medical
High-reliability medical device companies
Automotive
Tier 1 suppliers
IPC-9151 and Related Standards
IPC-9151 works alongside other IPC standards to provide comprehensive PCB quality management.
Related IPC Standards
Standard
Relationship to IPC-9151
IPC-6012
Defines acceptance criteria that PCQR2 tests verify
IPC-A-600
Visual acceptance that complements capability data
IPC-1710
Manufacturer Qualification Profile for supplier info
IPC-TM-650
Test methods referenced in PCQR2 testing
IPC-9252
Electrical test requirements
IPC-9151 vs IPC-1710
Aspect
IPC-9151 (PCQR2)
IPC-1710 (MQP)
Purpose
Capability benchmarking
Supplier qualification profile
Data type
Measured test results
Self-reported information
Verification
Third-party testing
Self-declaration
Comparison
Statistical peer ranking
Checklist comparison
Cost
Testing fees
Minimal
Objectivity
High (measured data)
Moderate (self-reported)
These standards complement each other: IPC-1710 provides supplier profile information while IPC-9151 delivers objective capability measurement.
The PCQR2 Program Legacy
The PCQR2 program operated from 2001 through 2023, providing over two decades of industry benchmarking data. While the active program has concluded, its methodology and impact remain relevant.
Program Timeline
Year
Milestone
2001
PCQR2 program launched
2002
IPC-9151 original release
2007
Revision B adds assembly simulation profiles
2012
Revision D with enhanced microvia testing
2017
New test patterns with improved HDI structures
2023
Active program concluded
Ongoing Value of IPC-9151
Application
Current Relevance
Internal benchmarking
Fabricators use methodology for self-assessment
Capability testing
Test panel designs remain valuable
Qualification programs
Methodology informs OEM supplier qualification
Process improvement
Framework guides capability enhancement
Industry knowledge
Historical data provides capability baselines
Frequently Asked Questions About IPC-9151
What is the difference between IPC-9151 and IPC-6012?
IPC-6012 defines the qualification and performance requirements for rigid printed boards, establishing what fabricators must achieve. IPC-9151 defines how to measure and benchmark the process capability used to meet those requirements. Think of IPC-6012 as the “what” (acceptance criteria) and IPC-9151 as the “how well and how consistently” (capability measurement). A fabricator might meet IPC-6012 requirements but have varying process capability. IPC-9151 PCQR2 data reveals whether they consistently produce at the center of specifications or are routinely at the edge of acceptability.
Is the PCQR2 program still active?
The PCQR2 program operated from 2001 through 2023 under Conductor Analysis Technologies (CAT) and IPC. While new database submissions are no longer being accepted, the IPC-9151 methodology remains valuable. Many OEMs continue using PCQR2-style test panels and analysis approaches for internal supplier qualification. The historical database data provides industry capability baselines. Fabricators who participated retain their capability documentation. The test panel designs and measurement approaches defined in IPC-9151 remain applicable for capability assessment.
How do I access PCQR2 database information?
During active program operation, database access was available to subscribers through Conductor Analysis Technologies. With the program concluded, access to historical data should be inquired about through CAT or IPC. Fabricators who participated in the program retain their individual capability reports. OEMs who were database subscribers may retain historical comparison data. For current supplier qualification, consider requesting IPC-9151-style capability data directly from fabricators or implementing internal PCQR2-type assessment.
What layer counts are available for PCQR2 test panels?
The PCQR2 program offered test panel designs in multiple layer counts to match fabricator capabilities and product requirements: 8-layer (entry-level complexity), 10-layer, 12-layer, 18-layer, 24-layer, and 36-layer (backplane complexity). The 2017 pattern updates focused on 8, 10, 12, 18, and 24-layer designs with enhanced microvia and HDI structures. Panel size was standardized at 18″ × 24″ to accommodate the various test structures. Fabricators typically selected layer counts matching their production capabilities and target markets.
Can I use IPC-9151 methodology for internal supplier qualification?
Yes, and many OEMs do exactly this. The IPC-9151 methodology provides a proven framework for capability assessment even outside the formal PCQR2 program. You can design capability test panels based on IPC-9151 principles, establish testing protocols per the standard’s approach, develop internal capability metrics using the five capability areas, create supplier comparison databases, and track capability trends over time. The key is applying consistent methodology across all suppliers for objective comparison. The IPC-9151 approach removes subjectivity from supplier qualification.
Altium: HDI Quality and Acceptability Requirements
Altium: Calculating Your Fabrication Capability Coefficients
Conclusion
IPC-9151 and the PCQR2 program represent a significant advancement in PCB supply chain management. By establishing standardized test panels, measurement methods, and comparison databases, the program transformed subjective supplier qualification into objective, data-driven benchmarking.
Key takeaways:
IPC-9151 defines PCQR2 – The benchmark standard for PCB fabricator capability testing
Five capability areas – Conductors/spaces, vias, soldermask, depth drilling, impedance
Standardized test panels – 8 to 36-layer designs with progressive complexity
Peer comparison – Statistical ranking against industry participants
Sourcing integration – Capability data drives qualified supplier selection
Methodology remains valuable – Framework applicable beyond formal program
Whether you’re qualifying new PCB suppliers, evaluating fabricator capabilities for complex designs, or establishing internal benchmarking programs, the IPC-9151 methodology provides a proven, objective approach to measuring and comparing PCB manufacturing capability.
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.
