Electromechanical Assembly Services
From wire harness fabrication to final system testing — we build complete electromechanical assemblies that combine electrical wiring, electronic modules, and mechanical hardware into production-ready products.
Electromechanical Assembly Services
We combine wire harness manufacturing, electronic assembly, and mechanical integration under one roof — eliminating multi-vendor coordination and quality gaps.
Wire Harness Integration
Complete wire harness routing, termination, and installation into enclosures, panels, and chassis assemblies
PCB & Electronics Installation
Mounting and connecting PCBAs, power supplies, displays, sensors, and other electronic modules
Mechanical Hardware Assembly
Fastener installation, bracket mounting, DIN rail assembly, and structural component integration
Control Panel Builds
Point-to-point panel wiring, terminal block assembly, relay mounting, and PLC integration
Enclosure & Chassis Assembly
Full enclosure builds with component installation, cable management, and environmental sealing
Functional Testing & Validation
End-of-line testing, burn-in, power-on verification, and customer-specific functional tests
In-House Wire Harness + System Integration
Most contract manufacturers outsource wire harness production, creating quality gaps and lead time delays. We build the wire harnesses and integrate them into the final assembly — one supplier, one quality system, one point of accountability.
- Complete wire harness routing and installation
- PCB and PCBA mounting with connector mating
- Mechanical hardware and fastener installation
- Point-to-point panel wiring per schematic
- DIN rail component mounting and wiring
- Terminal block assembly and wire termination
- Pneumatic and hydraulic component integration
- Conformal coating and environmental sealing
- Custom labeling, barcoding, and serialization
- Packaging and kitting per customer specification
The Single-Source Advantage
When wire harness manufacturing and system assembly happen under one roof, you eliminate the delays, miscommunications, and quality inconsistencies that plague multi-vendor supply chains. Changes propagate instantly from harness design to final assembly.
Get StartedFaster Lead Times
No waiting for harness deliveries — parallel production cuts weeks off your schedule
Better Quality
One quality system from wire cutting to final test — no incoming inspection gaps
Lower Cost
Eliminate supplier markups, shipping, and multi-vendor management overhead
Rapid ECOs
Engineering changes flow from harness design to assembly in hours, not weeks
Our Assembly Process
A proven 6-step process that takes your design from engineering review through tested, packaged product — with quality verification at every stage.
Design Review & NPI
Our engineering team reviews your assembly drawings, BOMs, and specifications. We conduct a Design for Assembly (DFA) analysis to identify optimization opportunities before production begins.
Material Procurement
We source all components — connectors, wires, PCBAs, hardware, enclosures — from our approved vendor network. BOM management and incoming inspection ensure quality from the start.
Wire Harness Build
Wire harnesses are built to your specifications using automated cutting, stripping, crimping, and soldering processes — all verified per IPC/WHMA-A-620 standards.
Mechanical Assembly
Hardware installation, bracket mounting, and structural components are assembled using torque-controlled tooling with documented verification at each station.
Electromechanical Integration
Wire harnesses, PCBAs, and electronic modules are installed and connected within the enclosure. Cable routing, strain relief, and connector mating are verified.
Test, Inspect & Ship
Every unit undergoes functional testing, visual inspection, and quality verification before labeling, packaging, and shipment with full traceability documentation.
Electromechanical Assembly Specifications
Our electromechanical assembly capabilities span a wide range of complexity levels, volumes, and industry requirements.
Industries We Serve
We build electromechanical assemblies for demanding applications across major industries — each with specific compliance and performance requirements.
Industrial Automation
PLC control panels, motor drive enclosures, sensor junction boxes, HMI panel assemblies
Medical Devices
Diagnostic equipment housings, patient monitoring systems, surgical device assemblies
Automotive & EV
Battery management systems, charging station assemblies, ECU enclosures, ADAS modules
Aerospace & Defense
Avionics enclosures, ground support equipment, radar sub-assemblies, mil-spec panels
Robotics & Automation
Robot controller enclosures, servo drive panels, end-effector assemblies, teach pendants
Telecommunications
Network equipment enclosures, power distribution units, fiber patch panels, antenna assemblies
“The biggest inefficiency I see in electromechanical assembly supply chains is the disconnect between wire harness manufacturing and system integration. When a contract manufacturer outsources the harnesses, every engineering change takes weeks to propagate, and quality issues get caught late — at final assembly instead of at the wire level. We solved this by keeping the entire process in-house. Our technicians who build the harnesses sit next to the team that installs them. Problems get caught and fixed in minutes, not days.”
China + Philippines Production
Our China facility provides rapid prototyping, NPI support, and full manufacturing capabilities for complex electromechanical assemblies. Our Philippines facility offers US tariff-free production for cost-sensitive volume programs — with the same quality systems and processes.
Custom Electromechanical Assembly Services for OEMs
Finding a reliable electromechanical assembly partner that can handle both the wire harness fabrication and the system-level integration is a persistent challenge for OEM purchasing teams. Most contract manufacturers either specialize in wire harnesses or in mechanical assembly — but not both. At OurPCB, we built our electromechanical assembly services specifically to bridge that gap: from wire cutting and stripping through final functional testing of the completed system, every step happens under one roof.
Our electromechanical integration capabilities begin with the wire harness and cable assembly build. We manufacture harnesses using automated crimping with force monitoring, soldering per IPC J-STD-001, and 100% continuity testing. These verified harnesses then move directly to the integration line — no shipping delays, no incoming inspection queues, no vendor coordination overhead.
The mechanical assembly phase covers everything from simple fastener installation to complex box build integration. Our technicians install PCBAs, power supplies, displays, sensors, and mechanical hardware using torque-controlled tooling with documented verification. For control panel applications, we perform point-to-point wiring per schematic, terminal block assembly, and DIN rail component mounting — the same work typically handled by specialist panel shops, but integrated with our wire harness capabilities.
Environmental protection is critical for many electromechanical assemblies. Our in-house overmolding, potting, and heat shrink capabilities provide IP-rated sealing and strain relief directly within the assembly process. For EMI-sensitive applications in medical and aerospace environments, we integrate braided shielding and shielded cables as part of the electromechanical build.
Quality assurance runs throughout the assembly process — not just at the end. Wire harnesses are tested before integration. Mechanical assemblies are verified at each station. Completed systems undergo functional testing with documented pass/fail criteria established during the NPI phase. Our quality system supports ISO 9001, IATF 16949 for automotive, and ISO 13485 for medical device applications.
For companies currently managing separate suppliers for wire harnesses and system assembly, consolidating to a single electromechanical assembly partner typically reduces lead times by 2–3 weeks, eliminates incoming inspection costs, and simplifies engineering change management. Our design support team provides complimentary DFA review during quoting to identify further optimization opportunities.
Ready to simplify your electromechanical assembly supply chain? Contact our engineering team to discuss your project, or request a quote with your assembly drawings and BOM. Most quotes are returned within 48 hours, and our NPI team can have your first articles built within 2–4 weeks.
Electromechanical Assembly FAQ
Electromechanical assembly is the process of integrating electrical components (wire harnesses, PCBAs, connectors, sensors) with mechanical components (enclosures, brackets, fasteners, chassis) into a complete, functional system. It goes beyond simple wire harness manufacturing — it delivers a finished, tested product ready for installation or end-use. At OurPCB, our electromechanical assembly services cover everything from simple sub-assemblies to complex multi-system enclosures with hundreds of connection points.
Box build typically refers to assembling components within an enclosure or box. Electromechanical assembly is a broader term that encompasses box builds plus any integration of electrical and mechanical systems — including open-frame assemblies, panel builds, chassis wiring, and sub-assemblies that may not involve an enclosure at all. Our electromechanical assembly services include box build as one of several integration capabilities.
We support the full production spectrum — from single-unit prototypes and engineering samples to high-volume production runs exceeding 100,000 units per year. Our dual-factory model (China for prototyping and full capabilities, Philippines for US tariff-free production) provides flexibility to match your volume requirements and cost targets. There is no minimum order quantity for prototype and NPI builds.
Yes — this is one of our key advantages. Unlike contract manufacturers who outsource wire harness production, we build the wire harnesses in-house and integrate them into the final assembly. This eliminates the communication gaps, quality inconsistencies, and lead time delays that occur when wire harness manufacturing and system assembly are handled by separate suppliers. One supplier, one point of contact, one quality system.
Every electromechanical assembly includes wire harness continuity testing, connector verification, and visual inspection per IPC/WHMA-A-620. Beyond that, we offer functional testing (power-on, signal verification), hi-pot dielectric testing, burn-in testing, and customer-specific test protocols. We develop custom test fixtures and procedures during the NPI phase and provide full test data documentation with each shipment.
Yes. Our engineering team provides Design for Assembly (DFA) and Design for Manufacturability (DFM) reviews at no charge during the quoting phase. We analyze your design for assembly efficiency, cable routing optimization, serviceability, thermal management, and testability. For customers without finalized designs, we offer full design support including wire harness drawing creation, BOM development, and 3D routing analysis.
Related Services & Capabilities
Box Build Assembly
Enclosure and system integration
SupportDesign Support
DFA/DFM engineering review
QualityTesting Services
Electrical and functional testing
ProductCustom Wire Harness
All harness types and configurations
ProductCustom Cable Assembly
200+ connector brands supported
ServicePrototyping
Quick-turn prototype builds
Need Electromechanical Assembly?
Send us your assembly drawings and BOM. We'll provide a DFA review and competitive quote — typically within 48 hours. From prototype to volume production, one supplier handles it all.