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Professional Wire Assembly

Wire Services & Wire Harness Assembly

Cusack Electronics delivers precision wire services covering wire cutting, stripping, wire crimping, wire termination, and complete wire harness assembly. From single prototypes to production runs, we handle custom cable assemblies with certified crimps, continuity testing, and full traceability.
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Who We Are

Creative Design
Uncompromised Quality.

As a leading electronic contract manufacturer, 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 concept to tech-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.
Learn More About Us

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
Machining EnvelopeUp 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 FinishRa 32 μin standard, Ra 16 μin or better achievable
Hole Diameter Range0.040" 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 Sizes1 piece prototypes to 10,000+ production runs
Inspection EquipmentCMM, optical comparator, micrometers, calipers, profilometer
Standards ComplianceISO 2768, ASME Y14.5, ISO 1302

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.

Everything Under One Roof

Design, PCB population, CNC machining, powder coating, UV printing, and full product assembly — all done in-house at our West Michigan facility. Fewer handoffs means faster delivery and tighter quality control.

Long-Term Partnership Model

We operate by the principle "help people help themselves." We invest in understanding your product deeply and become a true technical partner — not just a vendor taking purchase orders.

Scalable from Prototype to Production

Start with a single prototype, iterate quickly, and scale to production runs of 10,000+ units — all with the same team and quality standards. No re-quoting, no new supplier onboarding.

Music Industry Pedigree

We own two professional audio brands (Cusack Music and Mojo Hand FX) and design for many others. This real-world product development experience makes us far more than a typical contract manufacturer.

IP Protection & NDA

Your designs, schematics, and firmware stay yours. We sign NDAs on request and treat all client IP with strict confidentiality. We never share or reuse your proprietary designs.

100% American Manufacturing

Every product we build is designed and manufactured in the USA. No offshore outsourcing, no quality surprises. You get direct communication with the engineers building your product.

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

IoT & Connected Devices

Consumer Electronics

Automotive & Motorsport

Test & Measurement

View All Projects
Recent Work

Featured Projects

Professional Guitar Effects Pedal

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.
Learn More

Industrial IoT Sensor Gateway

Multi-sensor BLE gateway with Cortex-M4 processor, custom firmware, 10-layer PCB, and ruggedized enclosure — designed for factory floor deployment in harsh environments.
Learn More

Portable Patient Monitoring Device

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.
Learn More
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
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