Case Studies

PCB Assembly Case Studies - Express Delivery, Complex Projects, Real Results

Our expertise speaks through successful projects. Here are real examples of how Newmatik's express PCB assembly and flexibility solved critical challenges for our customers across multiple industries.

Case Study 1: Complex 14-Layer Rigid-Flex PCB - Zero Defects in 10 Days Express

The Challenge

A medical device manufacturer needed prototype assemblies of an extremely complex design:

• 14-layer rigid-flex PCB with multiple bend zones
• Multiple BGAs including 0.4mm pitch fine-pitch components
• Difficult-to-solder connectors requiring precise process control
• 10-day deadline for clinical testing
• Zero tolerance for defects due to medical application

Our Solution

Express Manufacturing Pipeline:

• Rapid DFM review and process engineering within 24 hours
• Customized solder profile development for rigid-flex assembly
• Vacuum vapor phase soldering for void-free BGA attachment
• 100% X-ray inspection of all critical joints
• Selective soldering for through-hole connectors

Quality Assurance:

• IPC Class 3 workmanship standards
• Full component traceability
• Detailed process documentation for regulatory submission

The Result

• Delivered in 10 working days exactly on schedule
• Zero assembly defects - passed first-time clinical testing
• Customer saved 6 weeks compared to alternative suppliers
• Series production order followed immediately

Customer Quote: "We didn't believe 10 days was possible for this complexity. Newmatik delivered perfectly."

Case Study 2: Supply Chain Reshoring - European Production Split Strategy

Case Study 2 — The Challenge

An industrial automation company faced mounting concerns with their 100% China-based PCB assembly:

• 12-week lead times from China causing inventory problems
• Geopolitical risks threatening supply security
• Quality issues requiring expensive rework in Germany
• Need to maintain cost-competitiveness while reshoring

Case Study 2 — Our Solution

Dual-Source Strategy:

• 50% production in Germany (Newmatik) for fast-turn and critical orders
• 50% remaining in China for lowest-cost high-volume runs
• Identical processes and documentation for both sources
• Quick-turn capability: 2-3 weeks vs 12 weeks from Asia

Risk Mitigation:

• Supply chain independence from single geographic region
• Ability to shift volumes based on geopolitical developments
• Local engineering support for design optimization

Case Study 2 — The Result

• Supply chain resilience - no longer dependent on single source
• Reduced inventory due to shorter lead times from Europe
• Improved quality - defect rates dropped by 60%
• Faster time-to-market for new product introductions
• Competitive total cost when factoring in reduced inventory and rework

Impact: Company now uses Newmatik for all NPI and express orders, with China production only for stable high-volume products.

Case Study 3: Large-Format LED Panel - 80x50cm Custom Production

Case Study 3 — The Challenge

An LED lighting manufacturer needed to produce large architectural lighting panels:

• PCB dimensions: 80 x 50 cm - too large for standard equipment
• Aluminum-core (IMS) substrate for thermal management
• Precise LED bin matching to ensure color consistency
• Volume production - 500+ units per month
• No suppliers willing to handle this format at reasonable cost

Case Study 3 — Our Solution

Custom Equipment Modification:

• Modified our pick & place machine to handle 80x50cm boards
• Developed custom fixturing for stable board handling
• Created specialized process for aluminum-core PCB assembly

LED Bin Management System:

• Implemented tracking system for LED batches
• Ensured consistent bin/batch within each panel
• Color temperature matching across production runs

Volume Production Setup:

• Optimized process for high throughput
• Implemented inline visual inspection for large-format quality control
• Cost-competitive pricing from Romania facility

Case Study 3 — The Result

• Successfully producing 500+ large-format panels monthly
• Perfect color consistency across all panels
• Cost reduction of 30% vs alternative European suppliers
• Reliable supply - never missed a delivery

Customer Impact: Architectural lighting project completed on time, customers impressed by color uniformity across entire building installation.

Case Study 4: Complete IoT Product Development - Hardware to Cloud

Case Study 4 — The Challenge

A large international HVAC company needed a complete IoT solution developed from concept:

• Hardware design for temperature/humidity monitoring
• Firmware development for sensor data processing
• Software/cloud backend for data visualization
• Enclosure design for industrial environments
• Turnkey production ready for market launch

Case Study 4 — Our Solution

Full Product Development Service:

• Electronics design: Custom PCB with STM32 microcontroller, sensors, WiFi/BLE connectivity
• Firmware: Real-time sensor data acquisition, local processing, cloud communication
• Cloud platform: Data storage, analytics dashboard, mobile app integration
• Mechanical: IP65-rated enclosure design, injection molding tooling
• Certification: CE/FCC compliance testing and documentation

Integrated Production:

• PCB assembly at Newmatik facilities
• Final assembly with enclosures
• Firmware programming and testing
• Packaging and fulfillment

Case Study 4 — The Result

• Complete working product from concept to production in 6 months
• Single point of contact instead of managing multiple suppliers
• Seamless integration - hardware, firmware, software designed together
• Successful market launch - now in volume production
• Cost-effective solution - no markup for coordination between suppliers

Customer Benefit: HVAC company could focus on their core business while Newmatik handled all technical development and production.

Case Study 5: From Supplier to Customer - Automating Our Own Shop Floor

Case Study 5 — The Challenge

Newmatik builds the electronics inside BITO's LEO automated guided vehicles. Our own plant in Hennweiler had exactly the problem those vehicles are built to solve:

• Several kilometres walked per shift by operators supplying the machines
• Material flow starting at goods-in, which also serves as outgoing inspection
• Batched transport trips driving larger buffers at every line
• Warehouse shelving consumed by material waiting far from the point of use
• Automation needed without rebuilding the factory or pausing production

Case Study 5 — Our Solution

One Vehicle, Many Stations:

• A single BITO LEO locative on a ring route around the entire plant
• Transfer stations at every point of use, handing over containers purely mechanically
• Navigation by data matrix markers beside the lane - no MES or ERP integration
• No building modifications: no floor works, no ceiling fixtures, no new aisles

Deliberate Scope:

• Transport layer decoupled from inventory booking, keeping the project to weeks
• Layout extendable by our own team without supplier support

Case Study 5 — The Result

• Operators back at the machines instead of walking the plant
• Less warehouse shelving needed - the transfer stations became the buffer, at the point of use
• Fewer errors through automated material provision
• Shorter throughput times across the whole material flow
• Supplier and customer in one relationship - we use LEO to build LEO

Customer Benefit: BITO gained a reference site running on their own product, and we gained the operational proof behind our automation claims. Read the full write-up.

Why These Projects Succeeded

Common Success Factors

Speed: Express service when deadlines are critical Flexibility: Custom solutions for unique challenges (80cm boards, complete development) Quality: IPC Class 3, zero-defect delivery, full traceability Communication: Direct contact with experienced engineers Supply Chain: European production with competitive Romanian pricing

Industries We Serve

These case studies span multiple industries:

• Medical devices (rigid-flex assembly)
• Industrial automation (supply chain reshoring)
• LED lighting (large-format production)
• IoT/HVAC (complete product development)
• Intralogistics (AGV control electronics)

Your project could be next. Whether you need express prototypes, complex assemblies, supply chain solutions, or complete product development, Newmatik delivers results.