Consumer Electronics.
Idea to Shelf, Under One Roof.
Cusack Electronics ranks among the consumer electronics manufacturers that take a product from concept to finished build without juggling vendors. Our consumer electronics engineering services pair in-house design, firmware, and PCB assembly with the quality control your launch depends on.
Jon Cusack
CONSUMER ELECTRONICS
A Single Partner for the Consumer Electronics Industry
From early-stage startups to established consumer electronics companies, OEMs come to us for speed, reliability, and one accountable team. We understand the cost pressure, tight launch windows, and quality expectations that define the consumer electronics industry, and we build process controls around them so your product ships on spec, on budget, and on time.
Connected & Smart Home
Wi-Fi and Bluetooth devices, hubs, and smart-home controllers with embedded firmware and connectivity built in from the schematic up.
Wearables & Personal Devices
Compact, low-power assemblies for fitness, health, and personal electronics, engineered for tight enclosures and long battery life.
Audio & Entertainment
Speakers, audio-effects hardware, and DSP boards backed by our in-house audio brands and decades of consumer electronics engineering.
Mobile & Accessories
Charging hardware, docks, and companion accessories built to consumer reliability and safety standards at production volume.
Appliances & Home Tech
Control boards, displays, and sensor assemblies for connected appliances that must survive years of everyday use.
Prototypes & New Products
Rapid prototyping, first articles, and pilot runs that move new concepts toward market without committing to hard tooling too early.
One Partner. One Workflow. Every Discipline.
What sets Cusack apart as a consumer electronics manufacturer is the integration of design, development, and production inside a single workflow. Your product never leaves our hands as it moves from electronics design and firmware to PCB assembly, machining, finishing, and final box build which means tighter timelines, fewer handoffs, and one accountable team.
Integrated Engineering
Electronics design, software development, and mechanical design teams work beside our manufacturing floor, accelerating iteration and protecting design intent through every revision.
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.
HOW WE WORK
From Concept to Delivery in Five Stages
A structured, transparent process built to reduce program risk, compress NPI timelines, and protect your margins from first prototype through full mass production.
Consultation
We review your product brief, BOM, and gerber files to scope the engagement, 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 obsolescence management and counterfeit-prevention controls that protect 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 & Fulfillment
Functional test, burn-in, and end-of-line test feed straight into our consumer electronics fulfillment services kitting, packaging, and just-in-time delivery into your channel.
Our other brands
Let’s Build Your Next Consumer Product
Send us your product brief, drawings, or a quick concept, and our team responds within 24 hours with a clear path forward engineering, manufacturing, and fulfillment in one place. When you need consumer electronics manufacturers who can design it, build it, and ship it, Cusack Electronics is ready to help.