Case Studies

Designing Proprietary End-of-Line PCB Test Equipment

Boosting our Q&A a notch above common industry standards, such as in-line ICT/MDA checks and optical/x-ray inspections, we developed a proprietary end-of-line functional tester from scratch, fabricating the external hardware and control panels, internal circuitry, and operating software. This tester is used for our PCB and OEM product builds, ensuring top quality for every unit shipped to our clients, while anticipating performance and reliability under real-world field conditions.

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Designing Custom-Made Switched Mode Power Supplies

One of our recent clients is a European switched mode power supplies (SMPS) manufacturer that designs power supplies for niche applications. Their products are custom-made and meet the specific electrical, mechanical, and certification requirements of each customer. All involved international safety, electromagnetic compatibility (EMC), and electromagnetic interference (EMI) standards are considered.

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Manufacturing High-Performance Vehicle Lights

One of the world’s leading OEM brands of electronic safety equipment produces a line of high-performance vehicle lights, including LED warning signals and directional beacons, which are commonly installed on fire engines, police cars, and recreational off-road vehicles. These types of lights must be especially durable for their operating environments, protected from water and dust in accordance with IP 67/68 standards: vacuum-sealed, impervious to water immersion below, and above one meter.

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RFID Tags for Mobile DNA Analysis Instrument

Modern DNA science has revolutionized law enforcement and military field operations, revealing, with all-but-indisputable accuracy, the identities of criminals or terrorists, or quickly exonerating the innocent, as well as correctly identifying human remains. Where such pinpoint analysis once took extensive testing by trained lab technicians, one U.S.-based company has developed a mobile, self-contained DNA analysis

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OEM Quality for Internal Pollution Monitor Assemblies

Since 2016, one notable client has been one of the world’s leading brands of industrial energy and environmental technologies. Their vast product catalog includes a line of stand-alone electronic monitors essential for controlling pollutants emitted within power facilities. Backed by the company’s long-standing reputation for reliability, the use life of these units in power plants has typically extended to 10 years or longer. With the goal of lowering manufacturing costs, and raising pricing margins, without impacting quality, the company sought a new turnkey manufacturing partner, who could successfully duplicate the internal PCBA design and outer housings of their existing pollution monitor products. Building upon our stellar track record of OEM electronics manufacturing services, we proved to be the ideal choice.

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Custom RFID Tags for Industrial Safety Harness Equipment

The safety products division of a Fortune 100 multinational conglomerate produces a brand line of industrial safety harnesses, designed to secure users against falls from bridges, oil rigs, scaffolding, or other elevated work areas. In addition to real-time tracking of this essential equipment, such as assigned user and current location, US OSHA standards require such harnesses to be inspected and re-calibrated at regular intervals. This company pioneered the incorporation of RFID technology into these harness products, with embedded tags programmed with each unit’s serial number, enabling each unit to be scanned and monitored for adherence to these mandated maintenance timelines, as well as meeting requirements of local regulators, insurance companies, and often management of the workplace itself.

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Designing Sensors for Dental Digital Imaging Systems

We’re able to offer incredible value on the design, fabrication, assembly, and testing of electronics products through a combination of high production standards and experience. Projects can often be modified to help meet a client’s budget, without compromising on the must-have features that make the product desirable in a crowded market. We achieves this through a collaborative design process, working with the client to establish which features are necessary and which can be replaced with a more cost-efficient feature set.

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Re-Engineering Electronic Elements for Induction Cooktops

An iconic global brand of household appliances sought a new OEM manufacturing partner for their induction cooktop coil assemblies and controller subsystems, following a falling out with their existing offshore vendor. Looking to start anew with a more accountable, proactive EMS relationship, they considered us after reviewing our superior track record developing similar heating components for consumer appliance OEM customers across international markets.

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Power Supply Product for Mobile Phone Base Stations

A recent client needed a power supply product that could stream clean, uninterrupted power to mobile phone base stations. These base stations were installed in areas where power was often unreliable, experiencing surges, fluctuations, and noise that could severely disrupt the proper functioning of the base unit and cause disruptions to the mobile network or damage to the base station itself.


RFID Tag & Custom Software for Denture Identification

A global dental prosthetics maker envisioned a new method for identifying and tracking dentures, from point of manufacture at the lab to end use among residents at nursing homes and other care facilities. While 23 U.S. states currently require some form of physical user identification on dentures, compliance has typically been very low. The reason being is that the added costs associated with engraving patient names on the dentures, as well as a user’s typical reluctance to reveal themselves as a denture wearer. In nursing facilities, because most dentures lack user names it’s often difficult to match individuals with their dentures after they’ve been routinely collected for cleaning and maintenance, or misplaced. These facilities also face potential HIPAA medical confidentiality violations if a labelled denture is mishandled and user identity is exposed beyond facility personnel. With the high costs of custom-made dentures and their day-to-day necessity for the user, this common problem called out for an innovative technical remedy.