Through Hole and General Assembly

There are still PCB assemblies requiring through hole components, required for robust connectivity, high voltage, certified products or legacy products Zeal can accomodate all through hole requirements and mixed technology assemblies. A 2020 investment in an ERSA ECOSELECT1 selective soldering machine allows us to provide repeatable quality for double sided mixed technology assemblies As part of our services we can also advise on production processes to allow assembly to be more cost effective

Cable Assembly

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. Ribbon cable assemblies. Specialist balun manufacture. 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
In addition we also assemble non-PCB assemblies such as battery packs and other electro-mechanical assemblies We have expertise on 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

Enclosure Builds

We also provide an enclosure assembly service. We can machine off the shelf enclosures to customer specification, manufacture bespoke plastic enclosures or can assist in having enclosures manufactured out of various materials
The enclosures can be supplied unassembled, part or fully assembled with connectors or cables as required. We can also provide a label to your specification with serial numbers, bar-codes, QR codes and customer logo’s We also have experience with 19” rack and control panel assemblies which we have assembled for the railway sector, power stations and the food industry

Encapsulation, Conformal Coating & Laquering

As required by some customers, we have the ability and expertise to be able to encapsulate products as required. Our dispensing equipment is setup to dispense two part mixtures
We also conformal coat and lacquer PCB’s and other items as requested using various approved products and various applications

Procurement

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

Engraving

In order to support our own manufacture of specialist, engraved components, we have extensive computer controlled engraving and plastic milling facilities
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
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 batches or dual sided assemblies The pick and place machines are augmented by a 10 zone re-flow oven achieving a fully controllable temperature profile (KIC profile and monitoring) for lead free and leaded assemblies, two Mycronic MY600 Jet Printers, and two MANTIS rework stations with 3D magnification to sustain the quality of the product 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

Inspection

Zeal has a 2021 Model K series 3D AOI machine from Mycronic at the end of the surface mount line. The department is also supported by two ScanSpection AOI systems. These machines are programmed for each individual assembly to allow the PCB’s to be inspected for missing, incorrectly fitted or wrong value parts. The 3D AOI machine can also inspect for poor solder ability and components that are not located correctly These machines can also be configured for mixed and through hole technology assemblies and using the comparator program they can compare an approved sample with another assembly to highlight any differences between the two All machines are connected to our company network and a capture of each PCB assembly is stored against the works order and unique serial number for full trace ability We can further inspect the solder ability of the PCB’s using our 3D magnification MANTIS inspection equipment

Through Hole and General Assembly

There are still PCB assemblies requiring through hole components, required for robust connectivity, high voltage, certified products or legacy products Zeal can accomodate all through hole requirements and mixed technology assemblies. A 2020 investment in an ERSA ECOSELECT1 selective soldering machine allows us to provide repeatable quality for double sided mixed technology assemblies As part of our services we can also advise on production processes to allow assembly to be more cost effective

Cable Assembly

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. Ribbon cable assemblies. Specialist balun manufacture. 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
In addition we also assemble non-PCB assemblies such as battery packs and other electro- mechanical assemblies We have expertise on 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

Enclosure Builds

We also provide an enclosure assembly service. We can machine off the shelf enclosures to customer specification, manufacture bespoke plastic enclosures or can assist in having enclosures manufactured out of various materials
The enclosures can be supplied unassembled, part or fully assembled with connectors or cables as required. We can also provide a label to your specification with serial numbers, bar-codes, QR codes and customer logo’s We also have experience with 19” rack and control panel assemblies which we have assembled for the railway sector, power stations and the food industry

Encapsulation, Conformal Coating &

Laquering

As required by some customers, we have the ability and expertise to be able to encapsulate products as required. Our dispensing equipment is setup to dispense two part mixtures
We also conformal coat and lacquer PCB’s and other items as requested using various approved products and various applications

Procurement

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

Engraving

In order to support our own manufacture of specialist, engraved components, we have extensive computer controlled engraving and plastic milling facilities
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
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 batches or dual sided assemblies The pick and place machines are augmented by a 10 zone re-flow oven achieving a fully controllable temperature profile (KIC profile and monitoring) for lead free and leaded assemblies, two Mycronic MY600 Jet Printers, and two MANTIS rework stations with 3D magnification to sustain the quality of the product 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

Inspection

Zeal has a 2021 Model K series 3D AOI machine from Mycronic at the end of the surface mount line. The department is also supported by two ScanSpection AOI systems. These machines are programmed for each individual assembly to allow the PCB’s to be inspected for missing, incorrectly fitted or wrong value parts. The 3D AOI machine can also inspect for poor solder ability and components that are not located correctly These machines can also be configured for mixed and through hole technology assemblies and using the comparator program they can compare an approved sample with another assembly to highlight any differences between the two All machines are connected to our company network and a capture of each PCB assembly is stored against the works order and unique serial number for full trace ability We can further inspect the solder ability of the PCB’s using our 3D magnification MANTIS inspection equipment