Electronic Contract Manufacturing Services & Custom PCB Assembly
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25+
Years of Excellence
10K+
Projects Assembled
48
States Served
99%
Client Satisfaction
Trusted Supplier for Industry Leaders
Multi System Design
We’ve worked on digital, analog, AC & and low power solutions
Automation
Automated assembly lines and product testing
Engineering
In house electrical, mechanical, and software engineers
Compliance
IPC & RoHS Compliant
Who We Are
Creative Design and Uncompromised Quality, Under One Roof
Cusack Electronics is a full-service electronic contract manufacturer built around a simple idea, that OEMs deserve a single partner who can take a product from concept through finished build without juggling multiple vendors. Our team brings electronics design, software development, mechanical design, and full-stack manufacturing capability into one accountable workflow, backed by years of hands-on engineering experience.
- Electronics design, software development, and mechanical design built into the same workflow as our manufacturing floor, eliminating handoffs between vendors.
- Workmanship governed by IPC-A-610 and IPC J-STD-001 standards across SMT, through-hole technology, hand soldering, and rework operations.
- In-house DFM, DFT, and DFA reviews catch design issues before production starts, reducing NPI cycles and protecting your margins.
- Lifecycle support covering BOM management, component sourcing, obsolescence management, and counterfeit prevention for long running programs.
What We Offer
End-to-End Manufacturing Services Under One Roof
Electronics PCB Assembly
CNC Drilling & Mill Work
Wire Services
Complete cable harness and wire harness assembly, including custom cut to length, crimping, terminating, soldering, and full continuity testing. Built for industrial automation, instrumentation, and electromechanical systems that demand reliable interconnects.
Powder Coating
UV Printing
3D Printing
Additive manufacturing for rapid prototyping, low-volume production, and custom tooling. FDM, SLA, and SLS workflows let us turn around enclosures, fixtures, jigs, and functional prototypes quickly without committing to hard tooling.
Injection Molding
Industries We Serve
Built for OEMs Across Every Electronics Sector
Manufacturing
Industrial automation controls, sensor boards, and ruggedized assemblies for production environments.
Industrial Automation
Embedded controllers, motor control boards, and instrumentation engineered for harsh field conditions.
Energy & Utilities
Consumer Electronics
Connected products and consumer devices with full design and manufacturing support.
Audio Industry
Audio effects products utilizing digital signal processors.
IoT & Instrumentation
Smart devices, sensor platforms, and connected hardware with embedded systems and firmware integration.
One Partner. One Workflow. Every Discipline.
Integrated Engineering
Electronics design, software development, and mechanical design teams work side by side with our manufacturing floor, accelerating iteration and protecting design intent.
Full Manufacturing Stack
PCB assembly, CNC machining, wire harness, powder coating, UV printing, 3D printing, and injection molding all happen under one roof, eliminating the need for multiple vendors.
Quality and Traceability
Workmanship aligned with IPC-A-610 and IPC J-STD-001, with documented traceability across approved vendor lists, lead-free solder lots, and full lifecycle records.
Industries We Serve
From Concept to Delivery in Five Stages
Consultation
We review your product brief, BOM, and gerber files to scope the engagement, whether turnkey or consigned, and align on milestones early.
Design & DFM
DFM, DFT, and DFA reviews refine your design for manufacturability before a single board is built, surfacing risks while changes are still inexpensive.
Sourcing
Component sourcing through our approved vendor list with built in obsolescence management and counterfeit prevention controls protects your supply continuity.
Assembly
SMT, through-hole, conformal coating, press-fit, hand soldering, and depaneling, all governed by IPC J-STD-001 workmanship and inline inspection.
Test & Ship
Functional test, burn-in, calibration, and end-of-line test, followed by just-in-time delivery with documented traceability into your facility.
Client Voices
What Partners Say About Working With Us
James Thompson
VP Operations
“When our main distribution panel failed on a Friday night, Cusack had an emergency team on-site within 2 hours. We were back online by Saturday morning. Incredible service.”
Sarah Kim
Facilities Manager · Regional Medical Center
Michael Rodriguez
Project Director · LogiChain Corp
Latest From Our Blog
Exploring how AI-driven PLCs and edge computing are reshaping factory floors across North America.
Common Questions
Frequently Asked Questions
What is electronic contract manufacturing?
Electronic contract manufacturing, often called ECM or EMS, is the practice of an external partner building electronic products on behalf of OEMs and ODMs. The scope typically covers PCB assembly, box build, testing, and supply chain support under one accountable engagement.
Do you offer turnkey and consigned manufacturing?
What PCB assembly capabilities do you offer?
Can you support new product introduction (NPI)?
What inspection and testing do you perform?
We run AOI, SPI, AXI, ICT, flying probe, functional test, boundary scan (JTAG), burn-in, HALT, HASS, and end-of-line test. The exact mix is calibrated to your product’s reliability targets and end use environment.
Which industries do you serve?
We serve OEMs across manufacturing,, industrial automation, energy and utilities, consumer electronics, telecommunications, IoT, and instrumentation. Process controls are adapted to each sector’s regulatory expectations.
How do you handle component obsolescence and EOL parts?
What compliance and certifications do you support?
Our processes align with ISO 9001, ISO 13485, IATF 16949, AS9100, RoHS, REACH, WEEE, UL, CE marking, FCC, and ITAR documentation requirements, with the specific framework matched to your program.
Do you provide product development services?
Can you handle the full product build, not just the boards?
Yes. Beyond PCB assembly, we offer CNC machining, wire harness assembly, powder coating, UV printing, 3D printing, and injection molding, allowing us to deliver a fully finished product under one roof.
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