Electronic PCB Assembly Services & Custom Board Manufacturing
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Who We Are
Production-Grade PCB Assembly.
Cusack Electronics is a full-service pcb assembly manufacturer bringing together engineering expertise, in-house fabrication, and a passion for precision, helping OEMs launch products from first prototype to mass production across consumer electronics, industrial automation, lighting electronics.
We operate under a straightforward principle: “Quality is not a checkpoint, it is built into every stage.” We value long-term build partnerships and apply our deep understanding of electronics manufacturing to every program we take on.
- Schematic and PCB design, DFM and DFA review, complete electrical engineering from gerber files to BOM-ready documentation.
- In-house SMT, through-hole and selective soldering, full PCB population using production-grade pick-and-place and reflow equipment.
- CNC milling, powder coating and UV printing, professional enclosures and finished assemblies built under one roof.
- Wire harnesses and full product builds, from individual populated boards to completely finished boxed products.
Our Services
9 In-House PCB Assembly Capabilities
Schematic & PCB Design
Altium Designer
KiCad
BLE / WiFi
Eagle CAD
IoT Ready
Multi-Layer
Firmware & Software Development
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
3D Modeling & Mechanical Design
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
PCB Population & Assembly
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
CNC Milling & Machining
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
Powder Coating
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
UV Printing
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
Wire Harness & Cable Assembly
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
Full Product Assembly
C / C++
RTOS
BLE / WiFi
Arduino
IoT Ready
How It Works | Technical Specifications
Our PCB Assembly & Build Process | Design Capabilities at a Glance
01
Discovery & Requirements
Consultation
Feasibility Study
NDA Available
02
Solder Paste & Stencil Setup
Schematic Capture
BOM Generation
Circuit Simulation
03
PCB Layout & 3D Modeling
Gerber Files
3D CAD
DFM Review
04
Firmware Development
Embedded C/C++
Unit Testing
Source Code Delivery
05
Prototyping & Testing
Functional Testing
Debug & Iteration
Client Approval
06
Production & Full Assembly
Production Run
QC Inspection
Packaged & Shipped
Technical Specifications
Design Capabilities at a Glance
PCB & Electronics Design Specs |
|
|---|---|
| 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 |
9 In-House Capabilities
Everything Under One Roof
PCB population, CNC machining, powder coating, UV printing, wire harness fabrication, and full product assembly all handled in-house. Fewer handoffs means faster delivery and tighter quality control on every program.
Long-Term Partnership Model
We invest in understanding your product deeply and become a true technical partner across your program lifecycle. We operate by the principle of helping clients succeed, not just processing purchase orders.
Scalable from Prototype to Production
Start with a single prototype, iterate quickly, and scale to production volumes of 10,000 units and beyond, all with the same team and quality standards. No re-quoting, no new supplier onboarding.
Consumer and Lighting Electronics Expertise
Our assembly capabilities extend into lighting electronics PCB assembly and consumer electronics PCB assembly, covering LED driver boards, control boards, and connected device hardware built to the same production-grade standards as every other program.
IP Protection & NDA
Your designs, schematics, and firmware are yours. We sign NDAs on request and treat all client IP with strict confidentiality. We never share or re-use proprietary designs across programs.
100% In-House Manufacturing
Every board we build is assembled and inspected inside our facility. No offshore subcontracting, no quality surprises, and no communication gaps between the engineers building your product and the people managing your account.
Equipment & Software
Machining Centers and CAM Software Powering Every Project
Haas Vertical Machining Centers
Horizontal Machining Centers
Mastercam
SolidWorks CAM
Zeiss CMM
Coordinate measuring machine for first article and in-process inspection
Mitutoyo Metrology
Carbide & HSS Tooling
Cutting Fluid Systems
Featured Projects
Ready to Build Your Next PCB Assembly Program?
Common Questions
Frequently Asked Questions
What is electronic PCB assembly?
Electronic PCB assembly is the process of populating a bare printed circuit board with components through SMT, through-hole technology, or mixed methods, then soldering, inspecting, and testing the board to a defined workmanship standard. The finished board becomes the functional electronic core of a product.
What PCB assembly technologies do you support?
We support surface-mount technology, through-hole technology, and mixed-technology assembly. Component types include 0201 passives, fine-pitch parts, BGA, QFN, QFP, MELF, DFN, and odd-form through-hole packages handled by hand soldering where required.
Do you offer lighting electronics PCB assembly services?
Yes. We assemble LED driver boards, dimmer control boards, power supply boards, and lighting controller PCBs for both prototype and production volumes. Lighting electronics PCB assembly programs follow the same IPC-A-610 and inspection protocols as our industrial programs.
Can you handle consumer electronics PCB assembly?
Yes. Consumer electronics PCB assembly is a core part of our work. We support connected device boards, audio electronics, handheld product internals, and high-mix consumer hardware with fast turnaround and full traceability.
What inspection and testing methods do you use?
We run solder paste inspection, automated optical inspection, automated X-ray inspection, in-circuit test, flying probe test, functional test, and first article inspection. The combination applied to each program is matched to your reliability requirements and end use environment.
Do you perform DFM review before assembly?
Yes. Every new program goes through a DFM and DFA review before any boards are built. We check your gerber files, BOM, and pick and place file for component spacing, pad geometry, thermal relief, via placement, and assembly risk before production starts.
What production volumes do you support?
We support prototype quantities from a single board through high-volume production runs of 10,000 units and above. The same team, equipment, and quality standards apply across all volumes, so your product scales without quality gaps.
Do you offer turnkey and consigned PCB assembly?
Yes. Turnkey assembly covers component sourcing, kitting, and full build from your BOM. Consigned assembly accepts customer-supplied materials and manages the build from incoming inspection through final test. We adapt to whichever model fits your supply chain.
What file formats do you accept?
We accept Gerber RS-274X, ODB++, IPC-2581, Eagle, KiCad, Altium native files, BOM in Excel or CSV, and pick and place files in standard XYRS format. For new programs, we prefer a complete package including gerbers, BOM, and assembly drawing.
How do you protect my intellectual property during assembly?
We sign NDAs on request before reviewing any proprietary files. Your design data, schematics, firmware, and BOM are never shared with third parties or reused across other programs. All client IP is treated with strict confidentiality throughout the engagement.