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Manufacturing Capabilities at ECS
Using state-of-the-art and proprietary technologies as well as the latest CNC equipment, ECS provides comprehensive manufacturing and assembly services under one roof. Our 80,000 square foot facility, centrally located in Franklin, Wisconsin, was built to support the exacting demands of the industries we serve. With significant large-production program experience, we are confident in our ability to rapidly mobilize every functional area of our company; expand effectively; hire and train manufacturing personnel; and customize floor plans and work processes to satisfy customer requirements for even the most challenging programs and the most aggressive schedules.
As an integral part of our robust in-house manufacturing capabilities, on-staff ECS manufacturing engineers (MEs) are available to support manufacturability and efficiency throughout every project. Our MEs review project drawings and develop supplemental manufacturing data sheets as necessary to address any customer revisions or manufacturing issues. Continually analyzing the process flow for ways to streamline production, improve turn-around, and reduce cost, the ECS MEs ensure that a final product not only meets all required specifications, but is competitively priced and efficiently built.
Production and Assembly Capabilities
Metal Fabrication
- Precision punching
- Forming and milling of high tensile strength aluminum and stainless steel alloys, using automated presses, bending brakes, and milling centers
- Resistance spot welding
- Fusion welding
- Laser metal marking for part and label marks
- Deburring
- Finishing operations
Mechanical Assembly
- Mechanical assembly of formed metal trays and shelves
- Design and construction of honeycomb panel assemblies using adhesive joining techniques and composite substrates
- Rivets and screw insert metal, joining assembly operations using fixed and mobile rivet machines
Electrical Assembly
- RF coaxial cables and connectors, data bus, and composite cable design and assembly
- Standard and custom wire harness fabrication and assembly that integrate aircraft-grade computer cabling and fiber optic technology when needed
- Automated and hand-held crimping tools
- Acceptance testing of harness assemblies using automated test equipment for high-pot, insulation resistance, connection resistance, micro ohmmeter bonding, and life-cycle testing
- Coaxial cable testing using network analyzers
- Laser, inkjet, and hot stamp wire markers for identification of wires and cables
- Automated wire stripping
- Plastic injection molding capabilities for custom cable connectors and strain-free components
