Project Overview

A fast-growing smart-lighting brand needed to move from prototype to volume production of its LED driver boards. Lacking in-house SMT capacity and juggling dozens of component suppliers, the customer turned to us for one-stop PCBA support — from BOM review and component sourcing to SMT assembly and functional testing.

The Challenge

• No internal SMT line; multiple vendors caused coordination overhead and delays.
• A BOM mixing LED lamp beads, driver ICs and passives across many suppliers.
• Tight time-to-market target for a new connected-lighting product.
• Requirement for consistent, repeatable quality at production volumes.

Customer Profile

The client is a smart-lighting brand supplying connected LED fixtures to residential and light-commercial markets across Europe and North America. After a successful crowdfunding launch, it needed to scale from a few hundred prototype boards to tens of thousands of units — without building an in-house electronics team.

Our Solution

We delivered a single, accountable service covering engineering, sourcing and assembly. Our engineers began with a design-for-manufacture (DFM) review, then optimised the BOM for cost and availability before sourcing every line item.

Because sourcing and assembly sat under one roof, change requests and shortages were resolved in hours rather than weeks. Full batch traceability gave the customer confidence for its own warranty commitments.

Results Delivered

• 30% faster time-to-market versus coordinating separate vendors.
• 18% total cost saving through BOM and source optimisation.
• 99.6% first-pass yield on production runs.
• Single point of contact for sourcing, assembly and quality.

Following a successful pilot, the customer moved its entire driver-board range to our PCBA service and now launches new models with a predictable, low-risk supply chain.

Beyond assembly, the customer gains a partner that can scale with demand: the same BOM, process and test programme can be replicated for updated models, and additional capacity is added simply by expanding the production schedule — with no retooling or re-qualification required on the customer's side.

Why It Worked

One-stop PCBA turns a fragmented supply chain into a single workflow. By owning everything from BOM to finished, tested board, we removed the delays and finger-pointing that hold hardware projects back — and gave the customer room to focus on product and market.

Planning a PCBA project? Send us your BOM and Gerbers for a free DFM review and quote.