PCB manufacturing operator handling large printed circuit board panels during inspection at Exception PCB’s UK facility.

UK PCB MANUFACTURING

High-technology PCB manufacturing from our facility in Tewkesbury, combining rigorous process control, experienced engineers, and the resilience of UK supply-chain manufacture.

WHAT WE MANUFACTURE

Exception PCB manufactures complex printed circuit boards at our 58,000 sq. ft UK facility in Tewkesbury, supporting customers across regulated and performance-critical sectors.

We build our manufacturing capability around process control, repeatability, and full visibility throughout production. Whether we are supporting early-stage prototypes or stable production volumes, the same engineering disciplines apply.

Our engineers bring deep process knowledge to every build, giving customers direct access to the expertise behind the manufacturing capability.

LET OUR ENGINEERS REVIEW YOUR DESIGN

Whether you are preparing for prototype or moving into production, our team will confirm the right manufacturing route and identify any risks before your build begins.


TALK TO OUR ENGINEERS

PCB MANUFACTURING PROCESS

Every PCB we manufacture follows a defined route, with inspection and verification integrated at each stage from design review through to dispatch.

STAGE 1

ENGINEERING AND CAM REVIEW

Design data is reviewed before production begins. Our engineers assess stack-up, materials, drill structures, impedance, and tolerances to confirm manufacturability and production intent.

STAGE 2

INNER LAYER IMAGING AND AOI

Inner layers are produced using precision imaging and etching. Automated optical inspection verifies track definition, spacing, and registration before lamination.

STAGE 3

LAMINATION

Inspected inner layers are laminated under controlled temperature and pressure, ensuring consistent bonding, resin flow, and layer alignment.

STAGE 4

DRILLING AND PLATING

Interconnections are formed through mechanical and laser drilling, followed by automated copper deposition to build conductive paths and via structures.

STAGE 5

OUTER LAYER IMAGING AND AOI

Outer circuitry is defined through imaging and etching, with automated optical inspection confirming pattern integrity and registration.

STAGE 6

ELECTRICAL TEST

All boards undergo 100% electrical testing to verify continuity and isolation across every net.

STAGE 7

FINAL INSPECTION AND DISPATCH

Completed boards are verified, documented, and dispatched with full material and process traceability maintained throughout.

An Exception PCB technician loading a printed circuit board panel into an ATG flying probe electrical test system.

QUALITY AND ASSURANCE

We support manufacturing quality through documented procedures, controlled process routes, and full traceability across production.

Our systems support:

  • AS9100 and ISO 9001 manufacturing standards
  • IPC Class 2 and Class 3 manufacture
  • Material and process traceability
  • Structured inspection and reporting
  • Controlled documentation

Customers benefit from clear visibility into how boards are manufactured, inspected, and released.

Learn more about our quality

ADVANCED PCB MANUFACTURING TECHNOLOGIES

Our manufacturing capability covers a broad range of PCB technologies, from standard multilayer construction through to HDI, flex, rigid-flex, RF materials, and hybrid builds. Detailed information on each technology area, including materials, construction approaches, and manufacturing considerations, is available on the pages below.

Technician holding a complex green rigid-flex circuit board panel with amber flexible interconnect extensions.

Flex & Rigid-Flex

Complex flex and rigid-flex PCB constructions for space-constrained and dynamic applications, built with reliability and repeatability in mind to support confident integration where weight, form factor, or movement are critical.

Macro view of a dark, high-density PCB showing precise gold pad layouts and trace routing.

HDI

High-density interconnect PCBs for fine features, microvias, and complex multilayer designs, manufactured using production-ready processes with full engineering oversight to ensure reliable and repeatable fabrication of the most demanding constructions.

Exception PCB operator loading a flexible printed circuit board panel into an ESI laser micro via drill processing system.

Advanced Materials

Support for specialist and hybrid PCB materials selected to meet thermal, electrical, and environmental performance requirements in applications where standard FR4 or conventional laminate systems cannot deliver the required performance.

Wide landscape view of an automated electrochemical processing line inside the manufacturing plant.

Copper Via Fill

Copper via filling for blind, buried, and through-hole vias, supporting HDI constructions, via-in-pad designs, and thermally demanding multilayer PCBs where electrical continuity, thermal performance, and consistent fill quality are required.

Macro close-up of ENIG gold-plated pads and precision circuit trace routing on a white substrate RF PCB, showing the surface finish quality and high-density layout of Exception PCB's RF manufacturing capability.

RF

RF and high-frequency PCBs built to support controlled impedance, low-loss materials, and consistent signal integrity in demanding applications where dielectric performance, layer registration, and material choice directly affect circuit behaviour.

Exception PCB technician in a white glove holding a green printed circuit board panel with four individual circuits.

Resin Via Fill

Resin via fill for blind, buried, and through-hole vias, providing consistent surface planarity to support via-in-pad designs, fine-pitch assembly, and sequential lamination builds where assembly quality and via integrity matter.

Exception PCB technician holding a flexible printed circuit board panel beside laser processing equipment.

WHY UK MANUFACTURING MATTERS

For many customers, PCB manufacture is about more than lead time alone.

UK PRODUCTION PROVIDES:

  • Reduced geopolitical and logistics risk
  • Greater visibility across the supply chain
  • Faster engineering communication
  • Improved protection of sensitive data
  • Support for reshoring and sovereign capability strategies

This gives our customers greater confidence at every stage of the programme.

Close-up of a large rack of copper printed circuit board panels awaiting processing, under PAL branding.

OUR INVESTMENT IN UK MANUFACTURING

We continue to invest in equipment, automation, and process capability to improve repeatability and manufacturing control.

RECENT INVESTMENTS INCLUDE:

This investment strategy supports both rapid development and long-term production scalability.

READY TO DISCUSS YOUR MANUFACTURING REQUIREMENTS?

Whether you are developing a prototype or scaling into production, our engineering team will help you choose the right approach.

RELATED ARTICLES

An Exception PCB technician storing green circuit board panels into a protective green slot rack cart.

Why UK Manufacturing Matters for Sovereign Capability

UK-based PCB manufacturing is no longer just a sourcing choice, it is a strategic way to reduce supply chain risk, protect sensitive programmes, improve lead times and strengthen sovereign capability in high-technology electronics.

Exception PCB manufacturing facility in Tewkesbury, UK, supporting high-technology printed circuit board production.

Exception PCB Brought Back into British Ownership

Wright Industries has acquired Exception PCB, returning the Tewkesbury-based PCB manufacturer to UK ownership as part of the Connexion Technologies group, strengthening national manufacturing resilience.

Exception PCB operator at the Orbotech Nuvogo 1000R laser direct imaging system in the cleanroom imaging area at the Tewkesbury facility

Exception PCB Installs Orbotech Nuvogo 1000R Direct Imager

Exception PCB has installed the Orbotech Nuvogo 1000R, a laser direct imaging system that strengthens our capability for fine line, HDI, flex and rigid-flex PCB production at our Tewkesbury facility.

RELATED PCB SERVICES

An Exception PCB technician loading copper production panels into a multi-station Schmoll CNC drilling machine.

Quick-Turn PCBs

Exception PCB's quick-turn service delivers accelerated PCB manufacturing for time-critical prototype and production builds, with the same process control and quality discipline applied to every order.

Side profile of a smiling Exception PCB engineer holding a flexible circuit sheet next to a micro via drill.

Design for Manufacture

Exception PCB provides engineering-led DFM review from an in-house team of ten engineers, identifying manufacturability risks and optimising designs before production begins. Available as an integrated or standalone service.

A smiling senior technician standing next to a Duetto Integrated Systems multilayer bonding machine at Exception PCB.

Research & Development

Exception PCB provides comprehensive engineering-led R&D support for new PCB materials and novel stack-ups. Our dedicated R&D team guides customers from initial requirements through to production-ready qualification and UL certification.

An Exception PCB technician looking through a protective glass window at an illuminated circuit board panel.

PCB Prototyping

Engineering-led PCB prototyping from our UK facility, supporting design validation, NPI, and low-volume manufacture for complex and high-technology applications. Every prototype is built to production-intent standards, reducing programme risk.