Case Studies

A special LED lens

We were approached by a lighting company with a unique requirement for a new type of LED that featured round and stick lenses. This LED presented challenges as it had sticky lenses, resulting in a high failure rate and significant parts lost. Other companies were reluctant to take on the project due to the associated complexities, prolonged downtime, and increased costs.

However, we accepted the challenge and conducted a test build. Recognizing the potential, we proactively collaborated with the LED manufacturer and engaged with specialized nozzle manufacturers. After investing considerable time and effort, we successfully designed various customized nozzles and fine-tuned the SMT parameters. As a result, we achieved close to 100% yield for mass production of this particular LED at a reduced cost.

Our success in meeting these demanding requirements attracted the attention of another lighting company based in New York, USA. They opted to utilize our services due to the combination of acceptable costs and superior quality compared to their Chinese providers.

Parts issue solution

When a client from Ontario asked us for help for a long lead time sensor, we couldn’t find it either. However when we reviewed the Bom and did a cross check of the sensor’s family we found stock for a different package with lower price so we suggested the client update the board with a footprint to fit both packages, so that they can use either module in future.

In another case, We designed daughter boards to fit a different footprint IC then soldered the daughter boards on the original PCB as it would be too expensive to redo the original PCB.

All these are add-on values we provide for our client without any extra charge.

Large and flex LED light sheet:

This local light company focuses on a large flex LED light board which is diffecult to build due to its diligent material and requiremnt of care during production. We only built control boards for them and never built the light board for them as they are already using a much larger company as their provider for the light sheet. After years of cooperation on their control boards, they started to try our service on a light sheet. We even upgraded the printer and SMT machines for our second production line, to fit the oversize flexable boards, and we got UL certified for that production line. We introduced many initiative processes tailored for their project to cut the price and improve the delivery turn time, and now we are the 2 of the main provider for them now.

Cost Saving

A kickstart startup compnay had a limited budget and wanted to reduce production expenses while ensuring their products remained reliable. We took on the challenge by researching and finding affordable alternative components that worked just as well. We provided clear cost analyses to help the startup company make informed decisions. Together, they optimized the PCB design to reduce complexity and waste. With our strong supplier connections, we managed to buy components in bulk and pass on cost savings. The result was a successful project with significant cost reductions, on-time delivery, and top-notch product quality.