New Product Introduction (NPI)
Design for manufacturing, testing and sustainability
Nearly 90% of a product's lifecycle cost is determined during the design phase — making early input critical to long-term success. Sunburst’s New Product Introduction (NPI) Program provides strategic guidance at the earliest stages of product development to help customers launch faster, reduce cost, and improve long-term quality and manufacturability.
By collaborating closely during design, we help ensure every product is optimized for real-world production, testing, and sustainability — from prototype to full-scale build.
Core Focus Areas:
Component Selection
Identify sourcing risks, avoid long lead times, and reduce costs through strategic BOM reviews.
Design for Manufacturability (DFM)
Optimize layouts for smoother assembly, fewer defects, and faster production.
Design for Testability (DFT)
Ensure efficient, scalable testing with smart design decisions from the start.
Design for Sustainability
Secure long-term supply with vetted vendors, multi-source options, and lifecycle planning.
Printed Circuit Board Assembly (PCBA)
PCBA is our core competency
At the heart of our operation is a commitment to precision, quality, and flexibility in Printed Circuit Board Assembly (PCBA). With over 40 years of experience supporting high-end industrial, medical, transportation, aerospace, and space-level applications, PCBA is our core competency — and the foundation of every program we deliver.
Our PCBA Capabilities:
Leaded and RoHS-Compliant PCB Assembly
We support both traditional leaded assemblies and RoHS-compliant processes to meet regulatory and environmental standards.
Advanced Component Assembly
Our facility handles the latest technologies, including:
BGA, µBGA
01005 (imperial) component size
4 mil fine-pitch
Through-hole components
Material and Board Versatility
We assemble across a wide range of board types:
Rigid, flex, and rigid-flex
FR-4, metal core, hybrid materials
Single, double-sided, and multilayer PCBs
End-to-End Development Support
From initial prototypes to full production, we support every stage of the product lifecycle with consistency and speed.
Value-Added Services
Enhance your board performance with optional services such as:
Conformal coating
Potting
Testing and inspection
Box Build
full box build, test and ship
Our Box Build Program is designed to extend the value of our core manufacturing services by offering full-system integration, assembly, and shipment — all under one roof. By combining Sunburst-produced PCBAs, custom wiring, cables, and enclosures, we help clients streamline their supply chains and bring fully assembled products to market faster.
We support both customer-supplied and Sunburst-manufactured components, with a flexible, quality-driven process that adapts to each project's unique requirements.
Box Build Capabilities Include:
Complete system assembly in metal or plastic enclosures
Integration of:
PCBAs
Cable and wire harnesses
Power supplies
Mechanical hardware
Embedded software or firmware (programming and configuration)
Functional testing and verification
Final packaging and direct shipment
Specialized Builds:
Explosion-Proof and Ruggedized Systems
Built to meet strict safety standards for hazardous environments, including oil & gas, mining, and industrial applications.Medical Device Assembly
Precision builds for regulated healthcare environments, following industry compliance protocols and traceability requirements.Large Cabinet & Control Panel Assembly
Custom cabinet builds for industrial automation, power distribution, and transportation systems, including multi-door enclosures.High-Complexity Data Server Integration
Custom box builds for immersion-cooled and air-cooled data servers used in AI, high-performance computing (HPC), crypto mining and edge environments. We support:Custom-designed cooling chambers and thermal solutions
Enclosure wiring, sensors, and embedded PCBA integration
System validation and power-up testing
