Small Team.
Big Impact.
Cusack Electronics builds industrial automation solutions that move from concept to finished product under one roof. As a full-service electronic contract manufacturer, we bring the engineering depth, manufacturing capability, and hands-on accountability that OEMs need to ship reliable products — on spec and on schedule.
Whether you are developing embedded controllers for factory floors or connected devices for field deployment, our team delivers the passion, precision, and flexibility to turn your design intent into production-ready hardware.
Jon Cusack
Industrial Automation Solutions
Industrial Automation Solutions Built for Every Electronics Sector
We deliver electronic contract manufacturing services engineered around the regulatory, performance, and traceability demands of each sector we support. From industrial automation systems that power factory floors to precision instrumentation deployed in the field, our process controls are adapted to meet the standards your industry expects — and your customers rely on.
Manufacturing
Industrial automation controls, sensor boards, motor drive assemblies, and ruggedized electronics built to perform in demanding production environments. We engineer industrial automation components that withstand vibration, heat, and continuous duty cycles while meeting the reliability standards your factory operations require.
Industrial Automation & Control
Embedded controllers, PLC interface boards, HMI modules, and industrial automation and control systems designed for real-time responsiveness in harsh field conditions. Our builds support open and proprietary communication protocols, enabling seamless integration into existing automation architectures.
Energy & Utilities
Power monitoring boards, grid-edge IoT assemblies, FPGA-based control units, and smart metering electronics for modern energy infrastructure. We support industrial process automation requirements across generation, transmission, and distribution — from substation relay boards to renewable energy inverter controls.
Consumer Electronics
Connected products and consumer devices with full design-through-manufacturing support. From wearable tech to smart home hardware, we handle the complete lifecycle — schematic capture, firmware development, regulatory pre-compliance testing, and volume production.
Audio Industry
Audio effects hardware, digital signal processor boards, amplifier modules, and professional sound equipment built with the precision that musicians and audio engineers demand. As the team behind Cusack Music and Mojo Hand FX, audio electronics is in our DNA.
IoT & Instrumentation
Smart devices, sensor platforms, data acquisition systems, and connected hardware with embedded systems and firmware integration. We build industrial automation technology into compact, field-deployable form factors — from environmental monitors to industrial-grade measurement instruments.
One Partner. One Workflow. Every Discipline.
What sets Cusack Electronics apart is the full integration of design, development, and manufacturing inside a single workflow. Your product never leaves our hands as it moves from electronics design and firmware through PCB assembly, machining, finishing, and final box build. For OEMs sourcing industrial automation solutions, this means tighter timelines, fewer handoffs, and one accountable team from prototype through production.
Integrated Engineering
Electronics design, software development, and mechanical design teams work side by side with our manufacturing floor, accelerating iteration and protecting design intent. Our engineers understand the demands of industrial automation systems and build for manufacturability from day one.
Full Manufacturing Stack
PCB assembly, CNC machining, wire harness fabrication, powder coating, UV printing, 3D printing, and injection molding — all under one roof. This eliminates the need for multiple vendors and gives you a single point of contact for every industrial automation component in your bill of materials.
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. Every industrial automation and control system we build ships with the compliance documentation your industry requires.
HOW WE WORK
From Concept to Delivery in Five Stages
A structured, transparent process engineered to reduce program risk, compress NPI timelines, and protect your margins from first prototype through full mass production. Every stage is built to support the complexity that industrial automation technology demands — with clear milestones, documented decisions, and zero ambiguity.
Consultation
We review your product brief, BOM, and gerber files to scope the engagement — whether you need turnkey industrial automation solutions or support at a specific stage. We align on milestones, identify risk areas early, and confirm that your design intent matches our manufacturing capabilities.
Design & DFM
Our DFM, DFT, and DFA reviews refine your design for manufacturing viability before a single board is built. We catch tolerance conflicts, suggest component alternatives, and verify that your industrial automation components are sourced for both performance and long-term availability.
Sourcing
Component sourcing through our approved vendor list, with built-in obsolescence management and counterfeit prevention controls. We protect your supply continuity so your industrial process automation hardware is never held up by a parts shortage.
Assembly
SMT, through-hole, conformal coating, potting, BGA soldering, and box build assembly — all governed by IPC J-STD-001 workmanship standards and backed by inline inspection at every critical step.
Test & Ship
Functional test, burn-in, calibration, and end-of-line test — followed by just-in-time delivery with documented traceability into your facility. Every industrial automation system ships with full test records and certificate of conformance.
Our other brands
Let's Coat Your Next Project
Send us your parts, color specifications, or a quick product brief, and our coating team will deliver a detailed quote with finish options, lead time, and sample panel recommendations within 24 hours.