Call for a Quote (510) 580-8500

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The largest EMS in the Silicon Valley

Call for a Quote (510) 580-8500

Or Email Us at

The largest EMS in
the Silicon Valley


PCBA – Design for Manufacturability

Whenever you bring a new product to market, there are many considerations and iterations required to find the optimal design. A key element that designers often don’t consider early enough is the ease of manufacturing the final product. When you’re focusing on adding functionality and improving the product’s durability, the PCB’s assembly requirements may seem inconsequential. However, design for manufacturability (DFM) is crucial to ensure the successful launch of your product.

What Is Design for Manufacturability?

Two distinct processes ensure your product’s manufacturability. Applying design for assembly (DFA) and design for fabrication (DFF) principles early in the product development process will save a lot of iterations and rework when finalizing the design.

Design for Fabrication

DFF focuses on issues relating to the fabrication of the boards. With DFF, the board’s layout considers not just the lines and bond dimensions but includes solving issues such as heat dissipation, connector location and any possible future updates to the product. By applying DFF design considerations early, you optimize both the PCB’s layout and cost before moving to the manufacturing stages.

Design for Assembly

Once you’ve optimized the DFF of the board, you’ll need to find the best assembly process for the final product. DFA ensures you develop the manufacturing process instructions (MPIs) that will make your product’s assembly run efficiently. Here at Sonic Manufacturing Technologies, we assist you by developing the required MPIs directly on an active production line.

Whether it’s a demo or development board, using active production lines during the prototype stages will ensure you find the optimal assembly processes early. It will also highlight any design deficiencies before they become showstoppers in the product’s manufacturing lifecycle.

Why You Need DFM for Your Printed Circuit Board

Design teams often leave the manufacturing considerations to the vendor. Once the vendor receives the design, they’ll conduct a manufacturability analysis and make the necessary changes to optimize the assembly process. If any disconnection exists between the designers and the manufacturing company, they may neglect communicating all the changes to the design team.

The impact of these changes could have drastic effects on the final product’s functionality. To eliminate the risks associated with this, getting the manufacturer involved early and collaborating with them during every iteration of the design is essential.

Sonic Manufacturing’s PCBA Design for Manufacturability Services

Sonic Manufacturing Technologies uses state of the art production lines to develop the MPIs and optimize the layout of the design. Our engineers can highlight any issues with the initial design and suggest changes that’ll improve your product’s feasibility.

Our services include:

At Sonic Manufacturing, we use an agile manufacturing process to ensure changes and updates do not disrupt any production runs. Additionally, our in-house engineering team will ensure you find an optimized assembly process for the product by developing an efficient MPI for any prototype or demo board.

Take Advantage of Sonic’s Manufacturing Optimization Processes

To guarantee your next product’s successful launch, partner with Sonic Manufacturing to ensure a smooth and efficient development process. Our state-of-the-art facility enables design teams to test designs and find optimized solutions for your product during the early stages of development.

When you need to optimize the design of a solid PCB, a flex board, or a combination of the two, you should get in touch with Sonic Manufacturing Technology’s talented team today.

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Considerations in Electronic Box Build Services

Inordinate amounts of considerations go into finding the perfect industrial design for your latest product. Is it functional? Does it serve an innovative need? Can it be cheaper? How long will it take to source from the manufacturer and assembler? All of these questions influence the final specification and layout of the product and are vital considerations in electronic box build services. Antoine de Saint-Exupéry famously said that you achieve perfection not when you have nothing more to add, but instead when there’s nothing left for you to take away from your creation.

The perfect design doesn’t just emphasize the functionality and usability of a product, it includes the aesthetics and user experience as core principles involved during the entire design lifecycle. The founder of Braun, Dieter Rams, established ten design considerations for engineers to subject each new product specification against before moving to the production phase.

Innovative Approaches to Electronic Box Build Services

A balance exists between creating something that is utilizable without compromising on its appearance. It should preferably also leave a lasting impression on end-users, fostering brand recognition in the longer term, and be designed for manufacturing with reduced errors and high efficiency. This may sound like a fantasy in traditional design and manufacturing cycles, as the next launch is always too soon, and the market’s expectations are too great to achieve a viable turn-around within these constraints.

This is exactly why agile design and manufacturing provides a new and innovative approach that helps product designers succeed in achieving such lofty goals. With agility as a cornerstone of the design and build lifecycle, entrepreneurs, startups, and established product designers can create continuous cycles of innovation and product improvement.

Sonic Manufacturing’s Agile Supply Chain and Electronic Manufacturing Services

At Sonic Manufacturing, we don’t necessarily consider change as a bad thing when collaborating with customers for electronic box build services. In fact, we may recommend a different backplane assembly or improve on your box frame and connector selections during the prototype or manufacturing stages. The primary goal is to improve your final product’s manufacturability and reliability, as well as accommodating for innovations discovered after your initial release to market.

Working with our customers, we assist with the initial wiring diagram creation and provide product layout services to find the perfect balance between function and aesthetic. As we prototype directly on the production line, the final specification includes all DFMA (Design for Manufacturability and Assembly) considerations at the outset of the project. Sonic Manufacturing understands that good ideas often come after the fact, and we designed our processes specifically to accommodate these situations.

Sonic Manufacturing’s electronic box build services include:

  • Product layout and assembly prototyping.
  • Housing design and weather tight finishing.
  • Supply chain logistics optimization with automated ecommerce solutions.
  • Adaptable forecasting and daily special runs.
  • Outbound and reverse logistics for improved order fulfillment.

Although our facility is in the US, we can ship products anywhere around the globe. We can also source components from the major OEM manufacturing zones using our International Procurement Office situated in Singapore.

Sonic Manufacturing as Your Agile Electronic Manufacturing Company

Sonic Manufacturing uses flexible, high-speed lines that assist with New Product Introduction as well as JIT or Kanban manufacturing processes for any level of volume. With our ecommerce component sourcing solution that handles the bulk of our procurement tasks, our team is free to focus on the primary goal of bringing your idea to fruition and find the perfect design for a sustainable product.

For more information regarding the primary considerations in electronic box build services, as well as product layout and manufacturing optimization, speak to one of Sonic Manufacturing’s expert production engineers today.

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High Tech Electronic Manufacturing in the Bay Area

High Tech Electronic Manufacturing in the Bay Area

“Imitation is the purest form of flattery”, said the English cleric Charles Caleb Cotton in the early 19th century. If that really is the case, we should be flattered! What started as a novel approach to beat the trends of sourcing electronic assembly from abroad has turned into a business model now copied by other startups in the Bay Area.

What Sonic Manufacturing has done that is different from everybody else is embrace change in an industry that considers it a dirty word. For companies who are always striving to push down the bottom-line, re-forecasting and order adjustments simply don’t work in traditional, waterfall methodologies. The difference Sonic brings to the table is an agile and lean production process.

Reforecasting at Your Leisure

Change is inevitable, but for supply chain and manufacturing operations, they can be business killers. It’s the nature of the business. Lines require retooling in order to adapt to changes, shutting down production for a period before new runs come online. At Sonic, this isn’t a big deal. In fact, it’s something we thrive on.

Technology Drives the Agile Facility and Manufacturing Processes

We are the leading electronic manufacturing services (EMS) provider in the Bay Area and our ingenuity has prompted other companies to copy our model.

According to a report published by the Bay Area Council’s Economic Institute, production and manufacturing is coming home. The report came 20 years after we had already successfully weathered the offshore storms and delivered a solution to companies that specialize in global innovation.

Innovating Manufacturing Cycles Before the Start of the Millennium

Three men started Sonic in 1996 with a vision that technology could actually deliver on the change-management capabilities it promised. This led to a supply chain solution that is intelligent enough to place 70% of all orders and constantly monitors the data to self-correct according to change.

It also resulted in a factory of 85,000 square feet that houses eight surface mount production lines. While production continues unabated, introducing new prototypes or manufacturing test runs happens with little or no fanfare. Outbound logistics hum along clearing the bays and delivering products in as little as one day lead times.

The Game Changer at Sonic Manufacturing

We provide all the services you may require as a peak production and manufacturing facility, but we don’t scoff at incubators and startups. Using the same assembly lines for both prototypes and the actual manufacturing, we don’t just test your product’s design feasibility—we determine how to build them quickly and cost-effectively, implementing changes rapidly.

New product introductions go through the analysis cycle quickly, speeding up your release to market. Manufacturing products using the benefits of close-proximity sourcing and an international buying office enables us to deliver on time, on budget and at the exact quantities you require.

Sonic Manufacturing Technologies is Essential in the Changing Economy

We serve the Bay Area including San Jose and Silicon Valley as well as Sacramento and Salt Lake City from our headquarters in Fremont, CA. With a seasoned team of experts and a willing attitude to do what’s required, we have provided the industry with a model worthy of copying.

Our services include every facet of the product design and manufacturing lifecycle, including component sourcing and finalization such as packaging and labeling. For electronic manufacturing that delivers quality products quickly, we set the trends that currently drive Silicon Valley’s electronic manufacturing industry.

For expert advice and guidance throughout the new product introduction process, contact Sonic Manufacturing Technologies on (510) 580-8500 or today.

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