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Delivering world class

contract electronics

manufacturing

Solutions for over 35 years.


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Full VersionConventional Assembly

Precision, consistency and high quality are features of this service. Many of the assemblies that we work on are for critical applications in the telecommunications field, and remote monitoring. It is therefore essential that our product is reliable in the field. Conventional work includes the assembly of complex electronic, electrical and micro mechanical components. Full testing procedures ensure product is delivered right first time and every time.

We have expertise on the bespoke assemblies serving the specialist needs of very large companies and the needs of SME's. Full flow soldering, cropping and test facilities, I/C programming, support the assembly operations. Many of our customers require full packaging of electronics, with power and controls, into both large and small enclosure systems.

Our services range from simple termination and connector assembly, to the production of complex looms and specialist cables. We have a great deal of experience in the following areas. Preformed power, alarm and control looms for enclosure assembly in the telecommunication and Control industries. Coaxial cable assembly and termination. Precision termination of “D” and miniature “D” connectors, including PCB incorporation into back shells. Fibre Optic cable assembly of patch cords, pigtails in both singlemode and multimode styles. Ribbon cable assemblies. Specialist balun manufacture, and assembly into cable interface frames.

All cables and looms are fully tested and coded to our customer's requirements and certified before shipment to their manufacturing or installation sites.

Cable and Wire Assembly LoomsSurface Mount Assembly

The Surface Mount section of Zeal’s Production process utilise 2 fully automated pick and place machines. With a dedicated team of trained Operators a Mycronic MY300LX with a 4K vision system provide the functionality of a system capable of placing up to 18,000 components per hour with an accuracy of placement accuracy of +/- 15um. This meets the requirements for all components including 01005 passives and the ultra-fine pitch/ BGA components.


The MY300 along with the MyCentre software suite allows us to setup the jobs from customer supplied data. This should enable us to run any job more efficiently, reducing machine times and providing a faster service to our customers.

Further efficiency coupled with a built in redundancy factor have been achieved through having a secondary surface mount line able to run independently or share the load of any large or dual sided assemblies.

The pick and place machines are augmented by a 10 zone reflow oven achieving a fully controllable temperature profile (KIC profile and monitoring) for lead free and leaded assemblies, two high performance screen printers and a rework station facility with a x30 magnification to sustain the quality of the product. We also have a BGA rework station with high definition cameras to enable us to efficiently remove and replace any BGA devices.


 Further efficiency coupled with a built in redundancy factor have been achieved through the networking together of two MYDATA machines. Common files are now shared from a server based Database thus reducing the time taken to initialise each machine and allow machine interoperability.

The pick and place machines are augmented by a 10 zone reflow oven achieving a fully controllable temperature profile (KIC profile and monitoring) for lead free and leaded assemblies, two high performance screen printers and a rework station facility with a x30 magnification to sustain the quality of the product. We also have a BGA rework station with high definition cameras to enable us to efficiently remove and replace any BGA devices.

Agilis feeders

We have a full range of Agilis feeders to a allow better pick rates on all components. This allows the best yield out of any materials either purchased by us or supplied by our customers.

Image © mycronic 2017

Image © mycronic 2017

Along with the MY300 we have also purchased the MYCENTER software to allow us to setup the jobs from customer supplied data. This should enable us to run any job more efficiently, reducing machine times and providing a faster service to our customers.

The variety of work we carry out for customers often displays cost benefits in supplying a comprehensive package of assemblies and components, for use in our customers’ production line assembly or site installation.

By controlling the supply chain on behalf of our customers we can offer a single source and control of component delivery. Such examples of procurement may include the supply of electronic assemblies, their interconnecting cabling, power wiring, fusing, tooling, and all of the fixings and consumables for final installation at site. Such practices can often save significant installation time and guarantee quality for customers.

In order to support our own manufacture of specialist, engraved components, we have extensive computer controlled engraving and plastic milling facilities.

In their simplest form we produce many identification labels for the electronics and control industries, in engraved plastic. Such identification systems may include cable ribbon buckles or control panel nomenclature.

By incorporating our hot wire bending facilities we can also produce complex shapes such as micro enclosures and covers, cable management and bend control assemblies, interface panels for connector bulkhead population. In many cases the parts are highly customised for duty and identification. In addition to standard typeface engraving, special logos and artwork can easily be incorporated.

As per customer requirement we have a dedicated routing machine which allows many proprietary enclosures to be machined to customer specification. This removes the need to outsource to another supplier which helps us control the lead times and quality of the final product.

ProcurementEngraving