Engineering & Design Services
El-Com Systems Solutions utilizes the full capabilities of our engineering resources to meet customer demands for engineering analysis, design, integration, manufacturability, and documentation support. Our engineering team brings over 30 years of mechanical design experience to our new product development, design for manufacturability (DFM*), and tooling design processes.
Complete Project Support
Each project we undertake is supported by a project engineer. This engineer supports the project team on all issues relative to production processes, technology, and engineering analysis, including assistance in product design phases and related design issues, moldflow analysis, customer approval of prototypes and first articles, and process improvement concepts to support DFM.
El-Com Systems’ engineers have an in-depth understanding of design processes and controls, and other engineering analysis functions and regularly participate in projects’ preliminary design reviews (PDR), critical design reviews (CDR), and product readiness reviews (PRR). Through our understanding of functional test and integration processes, we can provide superior service to our customers and consistent quality in every project.
We support customers in the transition from design to manufacturing, as well as to high-volume production in an offshore manufacturing environment. Our diverse manufacturing capabilities enable us to support new product innovation for higher-level assemblies, while our comprehensive engineering resources qualify us to make effective design and manufacturing recommendations to our customers.
Comprehensive Engineering & Design Capabilities
Our engineering department provides a variety of services and engineering analysis functions across numerous disciplines, including:
- Systems Engineering
- System architecture and specification
- Definition of test requirements and design of ATE (automated test equipment)
- Definition and implementation of software requirements
- Electrical Engineering
- Design of circuitry and electronics
- Expertise in optics, communication protocols, power, and thermal management
- Mechanical Engineering
- Manufacturing Engineering
- Design for manufacturability
- Process Requirements/Transition from Design to Manufacturing
El-Com Systems supports customers in transitioning from the design stages into manufacturing. We have diverse manufacturing capabilities which enable us to support new product introduction (NPI) for higher-level assembly. Our comprehensive engineering analysis resources enable us to make effective design and manufacturing recommendations to our customers.
We can work from your design files or collaborate to develop a completely new design that meets our customers’ requirements. Our engineering and design team uses an array of state-of-the-art design software, including SolidWorks, Pro-E, and Unigraphics for mechanical design, AutoCAD for drafting and mechanical parts, OrCAD for electronics design, and CFD simulations for thermal engineering analysis. Moldflow engineering analysis is an integral part of our design processes for injection molding tooling.
Engineering Qualification & ESS Testing
El-Com Systems designs and manufactures functional automated test equipment. We design custom test equipment to provide consistent results during production and to verify that the unit under test operates as designed. Our test equipment is designed to perform acceptance test procedures, including environmental stress screening (ESS) in accordance with customer requirements or as defined by El-Com Systems withcustomer approval. Our ATE systems are true open architecture and include test stations, software, fixtures, and complete documentation.
Temperature, humidity cycling, and burn-in testing are required on many of El-Com Systems’ products. We are familiar with environmental chamber testing requirements for both qualification and production ESS needs and burn-in.
Many El-Com Systems products must meet vibration requirements. We are familiar with vibration testing requirements for both qualification and production ESS needs.
Immersion leak testing for qualification and leak testing during production are common to sealed box assemblies, which El-Com Systems manufactures.
We also design and manufacture our own tooling fixtures and provide customers with a clear test plan for approval.
* Design for manufacturability (DFM) is the general engineering concept of designing products in such a way as to make them easy to manufacture. DFM focuses not only on making parts easier to manufacture, but also on minimizing use of materials and production time.