Advance Manufacturing

Building Reliable Energy Solutions to Withstand the Test of Time and Environmental Extremes

At Econis Labs, we continually advance our manufacturing capabilities by integrating cutting-edge technologies, including simulation, automation, robotics, digitization, and additive manufacturing. Backed by a trusted global supply chain, our flexible manufacturing models ensure efficiency, speed, and adaptability, meeting your time-to-market and product reliability requirements.

For products designed for 20 years of operational reliability, we employ a highly customized and boutique approach to manufacturing. Every step in our process is meticulously tailored to each product, featuring multiple layers of inspection—from visual and X-ray analysis of every PCB, to full functional stress tests. We also conduct accelerated load and stress testing, where samples from every production lot are destroyed under extreme conditions to validate manufacturing precision.

Our high-reliability manufacturing process cannot be easily duplicated or replaced by standard contract manufacturing, making Econis Labs the premier choice for complex, mission-critical energy products.

Leverage Our Proven Expertise in High-Quality Manufacturing Solutions

Design & Engineering Assurance

Where does design end and manufacturing begin? At Econis Labs, we ensure a seamless transition from concept to production, with a focus on delivering the reliability required by the energy sector. Our full suite of design and engineering services guarantees that your product is built to the highest standards, ensuring durability and long-term performance in the field.

We meticulously validate every aspect of your design, ensuring it aligns with industry specifications and operates reliably for over 20 years in demanding environments. From prototypes to final products, we optimize every step to minimize risk and accelerate time to market—delivering excellence that meets and exceeds your end goals.

Mechanical Design & Manufacturing

At Econis Labs, we have vertically integrated our mechanical design capabilities to deliver superior solutions tailored specifically for the energy industry. With a focus on precision and reliability, we provide in-house expertise in complex machining, including metal forming, plastics, and tooling, while also collaborating with trusted third-party partners for specialized needs.

From design and prototyping to small production runs, our team ensures seamless execution with the highest standards. Our global sites are equipped with state-of-the-art coordinate measuring machines (CMMs) and automated inspection systems to guarantee unmatched quality and accuracy. Whether internally or through our extended network, our mechanical design and manufacturing operations ensure that your products meet the rigorous demands of the energy sector.

Advanced PCBA Solutions

Econis Labs offers extensive experience and proprietary methodologies in advanced manufacturing to meet the quality, performance, and speed requirements of next-generation PCBAs, tailored to the unique needs of the energy industry.

Before assembly, we leverage finite element modeling to simulate real-world stresses, strains, and thermal impacts on the PCBA. This virtual environment allows us to optimize assembly processes and ensure solder joint integrity, delivering the highest yields with uncompromising quality.

From large, complex boards to 3D assembly, our industry-leading capabilities support a wide range of PCBA designs. We also specialize in System-in-Package (SiP) technologies, integrating multiple electronic components into one compact solution to help you achieve miniaturization goals.

Tooling Design & Fabrication

At Econis Labs, we specialize in delivering customized tooling design and fabrication solutions that meet the demanding requirements of the energy sector, withstanding harsh environments such as underwater exposure, high humidity, saltwater corrosion, and intense sunlight. Our extensive experience, coupled with cutting-edge technology, ensures that your components are built for durability and reliability, even in the toughest conditions.

From precision high-cavitation and close-tolerance tooling to rapid pre-production and spin stack molds, Econis Labs delivers turnkey solutions that meet your energy sector’s unique needs for high-volume, high-performance manufacturing in challenging environments.

Parylene Coating Deposition

For decades, Parylene coating has been the gold standard for high-precision, microscopic-level environmental protection across military, healthcare, and energy industries. However, due to the complexity of the process and the engineering expertise required, many in the industry have shifted towards more cost-effective but far less reliable protective technologies. At Econis Labs, we have specialized in Parylene coating technology, offering unmatched reliability and precision.

With three state-of-the-art deposition machines on our floor and over 2 million products successfully deployed in the field, we are leaders in Parylene coating technology. Our in-house capabilities include the design of custom fixtures tailored for each specific application, as well as custom primers that optimize adhesion and performance. We also utilize advanced laser microscopy to precisely measure deposition levels, ensuring the highest quality coating for every product.

Additionally, we offer UV traceability, embedding markers that allow for automated vision inspection of every PCBA, ensuring that the coating is applied uniformly and effectively. With over 12 years of expertise, Econis Labs delivers the highest level of environmental protection, ensuring your products meet the most demanding standards in the military, healthcare, and energy sectors.

Custom Potting Development

When it comes to environmental protection, there’s no one-size-fits-all solution. At Econis Labs, we specialize in developing custom potting materials and procedures tailored to the unique electrical, geometrical, and environmental requirements of each product. Whether your products face extreme temperature fluctuations, mechanical stress, or harsh environmental exposure, we create solutions that ensure long-term reliability.

Our expertise in potting development is backed by advanced laboratory capabilities, allowing us to design, test, and validate each custom solution. Using accelerated testing techniques, we prove the durability of our products, ensuring they perform under real-world conditions throughout their expected lifespan in the field.

With Econis Labs, you can trust that our custom potting solutions will meet the specific needs of your application, providing the highest level of protection for your products across the energy, military, and industrial sectors.

Quality & Efficiency

At Econis Labs, we blend manufacturing expertise with disciplined execution and Agile operations to deliver superior quality and efficiency. Our global manufacturing sites adhere to a strict ISO-certified quality management system, ensuring compliance with industry standards while continuously improving processes.

With a focus on eliminating waste and optimizing production workflows, we streamline manufacturing operations to increase productivity and reduce lead times. Our approach emphasizes efficiency without compromising on precision, ensuring consistent, high-quality results.

We use advanced process control and testing methodologies to reduce defects and maintain reliability across all product lines. Whether in healthcare, energy, or other regulated industries, we ensure our products meet the highest standards of performance and durability.

When you partner with Econis Labs, you can be confident in our ability to deliver high-quality, efficient manufacturing solutions tailored to your specific needs—ensuring you meet market demands with ease.

Tailored Manufacturing for Advanced Energy Solutions

Dedication. Expertise. Passion.

In today’s advanced industrial settings, especially for energy products integrated into critical infrastructure, a one-size-fits-all approach simply won’t suffice. At Econis Labs, we take a fully customized approach to manufacturing—where every aspect of the process is precisely aligned with the product’s specific operational environment.

The seamless integration of subassemblies, from PCBs to complex mechanical components, requires careful coordination. A fragmented approach—where design, manufacturing, and assembly occur in separate environments—leads to inefficiencies and compromises on reliability. We ensure that each phase, from initial design to final assembly, is conducted with precision and cohesion to guarantee the highest quality and performance for long-lasting energy products.

Precision-Driven Quality from the Start

At Econis Labs, quality begins with the very first component placed on a PCB. Every detail matters—from selecting the right component to ensuring laser-precise placement. Our advanced optical recognition systems analyze every part and process, ensuring that each step is executed to perfection. This meticulous approach is just the beginning of our commitment to delivering reliable, high-performance products for the energy sector.

Holistic Product Design for Maximum Reliability

At Econis Labs, product design goes far beyond just the electronics. Our engineering expertise ensures that every aspect—mechanical structure, geometry, and manufacturing processes—is carefully considered to guarantee long-term reliability. It's not enough to focus on individual components; the entire system, from subassemblies to final integration, must work in harmony. By aligning mechanical and electronic designs with precise manufacturing methods, we ensure that every product is engineered to perform flawlessly in the most demanding environments.

Dedicated Final Assembly in Controlled Environments

At Econis Labs, our final assembly—what we call end-of-line production—is performed in dedicated, positive-pressure, dust-free environments. Each production area is tailored specifically to the product being assembled, with precise control over humidity, temperature, and other environmental factors. This ensures the optimal conditions for assembly and potting materials, enhancing product reliability. A one-size-fits-all approach simply won’t deliver the quality required; our tailored processes guarantee exceptional performance for every product.

Custom In-Line Testing for Every Critical Manufacturing Step

At Econis Labs, we design and build custom in-line test fixtures for every critical stage of the manufacturing process. Each step is accompanied by unique firmware loads, executing different functions and stress tests to ensure peak performance. The process culminates in a final functional and operational test, where the finished product is rigorously tested before it moves to finished goods inventory. This thorough, multi-layered testing guarantees that every product is ready for shipment, meeting our high standards and ensuring customer satisfaction.

AI-Driven Custom Robotics for Precision Manufacturing

At Econis Labs, we are introducing custom robotics, supported by AI, at every step of the manufacturing process. This minimizes direct handling in stages that demand extreme reliability, achieving repetition levels with 9-digit precision. Our engineering team designs, manufactures, and programs these robotic platforms in-house, tailoring each system specifically to the product at hand. This approach ensures consistent, high-quality results while significantly reducing the risk of human error in critical processes.