Full-Service Electronics Design
Electronics Design & Build Under One Roof
From schematic and PCB design to firmware development, CNC machining, powder coating, and complete product assembly — Cusack Electronics is your single source for creative, high-quality electronic manufacturing in West Michigan.
Years in Electronics
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Products Designed
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In-House Capabilities
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USA Manufactured
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Get a personalized solution for your project within 24 hours.
Who We Are
Creative Design.
Uncompromised Quality.
As a leading electronic contract manufacturer in West Michigan, Cusack Electronics brings together engineering expertise, in-house fabrication, and a passion for innovation — helping clients launch successful products from concept to mass production.
We operate under the guiding principle: “Help people help themselves.” We value long-term partnerships and apply our deep love of electronics to every project we take on.
- Schematic & PCB design, firmware dev — complete electrical engineering from idea to BOM-ready files.
- In-house SMT, through-hole & selective solder — full PCB population using production-grade equipment.
- CNC milling, powder coating & UV printing — professional enclosures and finished assemblies under one roof.
- Wire harnesses & full product builds — from individual PCBs to completely finished boxed products.
Our Services
9 In-House Capabilities
Everything your product needs — designed, built, finished, and shipped — all from our West Michigan facility. No outsourcing, no delays.
Schematic & PCB Design
Full-cycle PCB engineering: requirements gathering, schematic capture, multi-layer layout, DRC/DFM checks, and Gerber file generation. We design analog, digital, mixed-signal, RF, and power boards.
Altium Designer
KiCad
BLE / WiFi
Eagle CAD
IoT Ready
Multi-Layer
Firmware & Software Development
Embedded firmware for microcontrollers (STM32, AVR, ESP32, PIC, ARM), bootloaders, communication stacks (BLE, WiFi, USB, SPI, I2C, UART), and custom application-layer logic for your hardware.
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
3D Modeling & Mechanical Design
Complete enclosure and mechanical design — from concept sketches to production-ready 3D CAD models. We model PCB mechanical fits, custom housings, mounting brackets, and full product assemblies.
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
PCB Population & Assembly
Production-grade PCB population supporting SMT (surface mount), through-hole, and combination boards. We handle 0402 passives and fine-pitch ICs with precision pick-and-place and reflow soldering.
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
CNC Milling & Machining
In-house CNC milling for aluminum, steel, brass, and engineering plastics. We produce enclosure panels, heatsinks, brackets, custom parts, and front panel cutouts with tight tolerances.
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
Powder Coating
Professional powder coating for metal enclosures and parts. We offer a full range of colors and textures (matte, gloss, textured) with durable electrostatic application and oven curing for a production-quality finish.
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
Full-Color UV & Direct Printing
Full-color UV printing directly onto metal panels, plastic enclosures, and product surfaces. Perfect for front panel labeling, branding, logos, knob legends, and production-ready product graphics — no labels required.
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
Wire Harnesses & Cabling
Custom wire harness design and manufacturing — from simple 2-wire cable assemblies to complex multi-conductor harnesses with connectors, terminals, heat shrink, and labeling for production builds.
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
Full Product Assembly
Complete product builds — we assemble all components (PCBs, enclosures, harnesses, hardware) into finished, tested, retail-ready units. From one-offs to production runs, fully assembled and box-ready.
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
How It Works
Our Design & Build Process
We guide every client through a structured, transparent process — from the first conversation to the final packaged product. No surprises, just results.
01
Discovery & Requirements
We listen deeply to understand your product vision, target market, technical requirements, and production goals. We define scope, schedule, and budget up front.
Consultation
Feasibility Study
NDA Available
02
Concept & Schematic Design
Our engineers create the circuit schematic, select components with an eye on cost, availability, and longevity, and perform simulation to validate electrical performance.
Schematic Capture
BOM Generation
Circuit Simulation
03
PCB Layout & 3D Modeling
Multi-layer PCB layout with DFM/DRC review, signal integrity consideration, and 3D mechanical design of the enclosure for complete product visualization before fabrication.
Gerber Files
3D CAD
DFM Review
04
Firmware Development
Embedded firmware written in parallel with hardware. We handle MCU bring-up, peripheral drivers, communication stacks, bootloaders, and application logic with full testing.
Embedded C/C++
Unit Testing
Source Code Delivery
05
Prototyping & Testing
We build functional prototypes in-house — PCB population, firmware flashing, enclosure machining — and rigorously test against all requirements before approving for production.
Functional Testing
Debug & Iteration
Client Approval
06
Production & Full Assembly
Once approved, we move into production runs — SMT/THT population, wire harnesses, CNC enclosures, powder coating, UV printing, and full product assembly with QC inspection.
Production Run
QC Inspection
Packaged & Shipped
Technical Specifications
Design Capabilities at a Glance
Our in-house equipment and engineering team handle a wide range of technical demands across all service areas.
PCB & Electronics Design Specs |
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| Machining Envelope | Up to 40" × 20" × 20" (VMC), 60" × 30" × 30" (HMC) |
| Minimum Tolerance | ±0.001" (0.0254mm) standard, ±0.0005" (0.0127mm) on request ±0.001" (0.0254mm) standard, ±0.0005" (0.0127mm) on request |
| Surface Finish | Ra 32 μin standard, Ra 16 μin or better achievable |
| Hole Diameter Range | 0.040" to 4.000" with drill bits, reamers, and boring bars |
| Thread Sizes | #2-56 through 1"-8 UNC/UNF, metric M2 through M24 |
| Materials Supported | Aluminum, steel, stainless, titanium, brass, copper, plastics |
| Axis Configuration | 3-axis, 4-axis, 5-axis milling |
| Batch Sizes | 1 piece prototypes to 10,000+ production runs |
| Inspection Equipment | CMM, optical comparator, micrometers, calipers, profilometer |
| Standards Compliance | ISO 2768, ASME Y14.5, ISO 1302 |
Software & Equipment
Tools We Use
Professional-grade EDA, CAD, and manufacturing tools powering every project we deliver.
Altium Designer
PCB layout & schematic
KiCad EDA
Open-source PCB design
Eagle CAD
Schematic & PCB design
SolidWorks
3D mechanical modeling
Fusion 360
3D design & CAM machining
LTspice
Circuit simulation
OrCAD
Professional EDA suite
In-House SMT Line
Pick-and-place & reflow
Markets We Serve
Industries We Design For
Professional Audio
Industrial Automation
Medical Devices
IoT & Connected Devices
Consumer Electronics
Automotive & Motorsport
Test & Measurement
Defense & Aerospace
Recent Work
Featured Projects
Full design and production of a boutique analog delay pedal — from schematic, PCB layout, and firmware to CNC aluminum enclosure, UV printing, and final assembly.
Multi-sensor BLE gateway with Cortex-M4 processor, custom firmware, 10-layer PCB, and ruggedized enclosure — designed for factory floor deployment in harsh environments.
Low-power embedded system with BLE connectivity, high-accuracy analog front end, 6-layer PCB, injection-molded enclosure design, and IPC-A-610 Class 3 assembly.
Recent Work
Ready to Design & Build Your Next Product?
Full design and production of a boutique analog delay pedal — from schematic, PCB layout, and firmware to CNC aluminum enclosure, UV printing, and final assembly.
- Free initial consultation, no obligation
- NDA available for IP protection
- Prototype to production, all under one roof
- 100% USA designed & manufactured