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Your Go-to Partner for Build-to-Print Services 

Our experience as a leading supplier of highly reliable power solutions positions us to be an ideal supplier for Build-to-Print (BTP) manufacturing and test services for military applications. For decades, we’ve been a major supplier for custom designed power supplies for the world’s most demanding defense applications and environments. With our expertise and in-house manufacturing and test capabilities, we’re the go-to partner for BTP services.

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What is Build-to-Print?

Build-to-Print (BTP) is exactly what it sounds like—manufacturing, or building, products to a customer’s work instruction. When partnering with us for BTP manufacturing, we’ll use your ready-made engineered designs and our technical expertise and operational efficiencies to build your design to your specs. BTP solutions are perfect for customers who have engineered their own power supply unit, but need a manufacturing partner to bring it to life. Our vertical integration and in-house capabilities make us the perfect BTP partner for reliable power supplies.

Build-to-Print Capabilities

The majority of the space of our 63,000 sq. ft. facility is dedicated to manufacturing. AT ACT, our operational capacity enables the efficient manufacturing and delivery of high mix, low volume assemblies. Our philosophy at ACT supports consistent control of the manufacturing process, which guarantees excellent performance, cost efficiencies, and timely deliveries to meet the critical demands of BTP customers.

Our internal resources uniquely position us to offer an extraordinary variety of production services. We also produce various types of enclosures as well as many of the components, like transformers and chokes, for such assemblies. This, coupled with our extensive in-house capabilities and processes, allow us to meet your design goals. Our legacy centers on the design and fabrication of complex power supplies for defense applications, so we’ve got the ability and the know-how to be your BTP power partner.

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Manufacturing & Test Technologies

The manufacturing techniques we’ve developed at ACT are continuously monitored, revised, and upgraded to remain current with customer and industry demands. Assembly and test techniques include pick and place automation and hand placement of parts. Our in-house design and fabrication capability for assembly and test provides our customers with convenience and confidence. In addition to our BTP production floor management tools, like our fully integrated enterprise resource planning (ERP) system and operator certification program, here are some manufacturing technologies we offer in-house by our trained and experienced staff:

  • Fully equipped modern metal working shop for fabricating and machining chassis and enclosures
  • CAM software—directly linked to CAD system allowing our engineering department to send a CAD drawing into the metal shop—giving us the ability to have parts fabricated within hours
  •  CNC and conventional machining centers, including water jet machining—the water jet cutter can be used to cut complex patterns in aluminum, steel, copper, fiberglass, and many other materials
  • Punches (CNC and conventional)
  • Shears
  • Brakes (CNC and conventional)
  • Lathes grinding/sanding
  • Tinning/soldering
  • Machining and sheet metal fabrication
  • Plating and chem film line—chemical conversion coating to MIL-DRL-5541, types I and II and electro tin plating
  • Painting
  • Silk screen marking
  • Toroid winding machines
  • Bobbin winding machines
  • Coil winding machines
  • Encapsulation (potting, varnish, etc.)
  • Automatic surface mount pick and place
  • Automated printed circuit board assembly
  • CNC leaded and surface mount component locator
  • Lead forming/tinning
  • Conformal coating
  • Encapsulation—potting/hermetic sealing/thermal desiccation, proprietary dielectric oil-gas filling
  • Roll soldering
  • Flex circuits
  • Silk screening
  • Surface mount soldering and solder paste stenciling
  • Adhesive dispensing
  • Automatic Optical Inspection (AOI)
  • Electrical and mechanical assembly
  • IPC/EIA J-STD-001 certified soldering experts
  • Workmanship to IPC/EIA J-STD-001 and MIL-HDBK-454
  • Cleaning done in environmentally safe cleaning systems
  • Wire cut and strip machining
  • Torque wrenches
  • Air tools
  • Crimping equipment
  • Chassis wiring and assembly
  • Cable assembly
  • Potting, staking, and conformal coating
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We also use current testing methods and equipment. Each assembly is tested and visually inspected to ensure it was manufactured in accordance with applicable procedures and standards. Every unit produced is 100% tested to customer specification. Here are some electrical and environmental test details performed by our skilled technicians at dedicated workstations:

Testing

  • Calibration program
  • Automatic test equipment
  • High and low voltage electrical
  • Vibration: sine and random, all three axis for both qualification and ESS
  • Temperature: -55°C to +105°C for both qualification and ESS
  • Temperature/altitude
  • Temperature/humidity
  • Thermal cycling
  • Thermal shock
  • Coordinate Measurement Machine (CMM)

Government/Industry Standards

  • ACT’s quality system is certified to AS9100D and ISO 9001:2015
  • ANSI/J-STD-001 (certified trainer in-house)
  • Various in-house standards based upon procedures in MIL-STD-883, MIL-STD-202, J-STD-001, and IPC-610
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Our Expert Staff

Our staff at ACT has a low turn-over rate and complete understanding of how BTP services support the overall mission of the company. Production employees receive a variety of in-house training applicable to their jobs, including courses in J-STD soldering, ESD, hazmat, documentation use, rework processes, and OJT. We ensure that employees are cross-trained for critical needs and support.

We maintain a first shift that is capable of rapid expansion—giving us the ability to operate a second shift when needed to meet increasing demand and to significantly increase our capacity. When partnering with us, customers are given direct points of contact, which yields outstanding communication and timely problem resolution.

Quality Assurance

ACT’s quality system is certified to AS9100D and ISO 9001:2015 and valid for the design and manufacturing of rugged, custom power supplies and electronic devices. Our quality assurance operations address incoming inspections, in-process inspections, and final inspections, including data analysis and corrective action programs to ensure the highest quality products.

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