Costs to Expect in Panel Design and Build
Designing and building an industrial control panel is more than just wiring components into an enclosure. It involves engineering expertise, code compliance, quality craftsmanship, and the ability to meet both immediate production goals and long-term operational needs.
Costs can vary widely depending on the project. But understanding the factors that influence those costs—both obvious and hidden—can help you set realistic expectations and avoid surprises during the process.
Core Cost Drivers
Panel Type and Scope of Control
What the panel needs to do will shape both the design and the cost. A basic on/off motor control setup is far simpler than a full-featured automation panel controlling multiple processes across a production line.
Things that tend to increase scope:
The number of devices being controlled
Zones of automation
The need for remote access or system-wide integration
Safety or redundancy requirements
Panels that integrate PLCs, HMIs, safety relays, or communication modules will naturally require more engineering time, more complex layouts, and more sophisticated programming.
Components and Specification Choices
The components inside the panel are a major cost driver. Prices can vary significantly depending on:
Brand and model
Required certifications (e.g., UL, CE)
Specialty functions (e.g., safety, high-speed I/O, network redundancy)
Specifying industrial-grade parts for harsh or regulated environments can increase cost but often pays off in durability and support. The choice between commodity parts and proven brands like Allen-Bradley or Siemens can influence not only pricing, but long-term maintainability.
Enclosure Design and Environmental Factors
Enclosures aren’t just boxes—they're critical to protecting components and meeting safety standards. Design considerations include:
Material (e.g., steel, stainless, or polycarbonate)
Environmental rating (e.g., dust, moisture, washdown, temperature extremes)
Mounting type (wall, floor, or machine-mounted)
Whether cooling, heating, or air filtering is required
Custom enclosures or those designed for food-grade or outdoor environments will generally require more engineering and fabrication time.
UL 508A Certification and Compliance
If the panel needs to be UL 508A certified—a common requirement for manufacturers and OEMs—there are additional steps to account for. These include using UL-recognized components, specific wire types and markings, and adhering to strict design documentation and labeling standards.
While UL listing adds cost and complexity, it also helps with inspection readiness, safety assurance, and long-term liability protection.
Labor and Assembly Time
Wiring a control panel is a detailed, hands-on process. Neatly routed wires, precision labeling, torque-checked terminals, and full system testing all require skilled labor.
Factors that affect assembly time include:
Quantity and density of devices
Wire routing complexity
Custom features like multi-door layouts or internal partitions
Testing procedures and quality checks
Well-designed panels take labor into account from the start—because a tight layout that’s hard to wire or maintain can end up costing more in the long run.
Engineering and Documentation
Good control panels start with good engineering. In addition to layout and component selection, the panel design team typically produces:
Schematics and wiring diagrams
Panel layout drawings
Bills of materials
Wire schedules and labeling standards
Programming for PLCs, HMIs, or other intelligent devices
Testing plans and documentation for compliance or UL review
This work is often unseen, but it's critical to building panels that are safe, scalable, and easy to maintain or troubleshoot years down the road.
Costs That Are Easy to Overlook
Certain costs don’t always appear in the initial quote but can become important later:
Changes to the project scope after kickoff
Custom labels, drawings, or compliance documentation
Travel or on-site startup support
Shipping or rigging for large or heavy panels
Planning for future expansion (space, power, I/O)
Asking your integrator or panel shop about these items up front can help avoid budget surprises and ensure the design meets your long-term needs—not just the immediate build spec.
Getting a More Accurate Estimate
The best way to reduce pricing uncertainty is to come to the table with a clear scope. That doesn’t mean every detail must be finalized—but the more information you can share early, the better.
Useful inputs include:
Number and type of devices being controlled
Preferred control architecture (relay, PLC, HMI, SCADA)
Environmental and safety requirements
Any existing drawings, schematics, or documentation
Whether programming, commissioning, or certification is needed
Working with an experienced team can also help you identify areas to reduce cost without compromising safety or functionality.
Final Thoughts
Industrial control panel costs are shaped by more than just parts and labor. The decisions made during engineering—component selection, layout strategy, future flexibility—have lasting impacts on safety, reliability, and lifecycle cost.
While it’s tempting to chase the lowest quote, investing in thoughtful design and high-quality fabrication often results in fewer headaches, better uptime, and easier maintenance over time.
If you're preparing for a new build or upgrade, clarity in scope and collaboration with a knowledgeable partner will go further than any spreadsheet can show.
Let me know if you'd like this article adapted for a project proposal, quote request guide, or email campaign.