When demand surges for complex, industrial-scale products, many OEMs hit a wall. Space runs out. Supply chains strain. But here’s how you can grow without the pain.
When growth is a good problem to have
It’s an exciting moment for any OEM when a product takes off and orders surge. But behind the scenes, operational challenges may be growing. The reality of increased orders can mean a scramble to meet demand.
The nagging question for many operations keeps coming up:
Where do we find the capacity to deliver everything on time and on budget?
The hidden challenges of scaling mechatronics
Luckily, scaling up within standard electronics manufacturing is usually straightforward. While commercial risks can increase and it may be hard to expand at the pace you need, there are ways you can meet demand fast.
You might need more assembly cells, possibly extra SMT machines (if volumes grow significantly) and more supply chain capacity. Generally, though, there will be enough resources and outsourcing options available to support your expansion.
But meeting new demand for large-format mechatronic assembly?
That’s a different matter.
Industrial machinery requires space and skill to put together
Large-format assembly projects present unique challenges around manufacturing scale and complexity
Units that are two to three metres wide require lifting equipment, vast floor space, uniquely qualified labour, specialised testing and logistics to assemble and deliver.
But the challenges don’t end there.
Mastering the mechatronic supply chain
When it comes to electromechanical assembly, the supply chain is often fragmented. It includes made-to-drawing parts such as machined items, fabricated sheet metal, cable looms, and plastic elements.
In addition, you’ll need access to electronic devices and off-the-shelf modules.
Each of these components typically involves different suppliers - all requiring their own relationships, logistics coordination, and precise timing to ensure you can meet growing demand.
It's not just a case of "hiring a few more technicians” - it may be a case of transforming how and where you work - as well as who you work with.
Mechatronic assembly outsourcing: a case study
Recently, a long-standing customer approached our company, ESCATEC, with an urgent request.
Could we deliver a large batch of electromechanical machines to a North American client, fast?
These weren’t small units. These were bulky, industrial-grade mechatronic assemblies complete with control cabinets destined for a new market. It was a strategic opportunity that could unlock major expansion with a leading U.S. retailer.
Stephen Greaves, Director of Customer Service, ESCATEC
The order wasn’t part of their annual forecast, either. It was a high-stakes, time-critical opportunity with zero margin for delay. ESCATEC was one of the few global suppliers who had the space, resource and flexibility to respond.
Three critical ways ESCATEC solved for mechatronic growth
With ESCATEC's unique blend of global facilities and skills we were able to:
1. Free up critical production space by relocating 300 pallets of existing raw materials to a temporary warehouse a few miles away.
The new space was secured under a short-term lease and rapidly refurbished to meet safety and operational standards. The existing space was then converted into several new production cells capable of meeting increased production demand.
Alex Paice, Business Unit Manager, ESCATEC
2. Create a dedicated material coordination team to manage complex BOMs, secure long-lead-time parts, and maintain daily contact with suppliers across the globe - line-by-line, part-by-part.
3. Deploy global labour resources fast, relocating two engineers and four operators from Malaysia to the Czech Republic in just one week—to increase immediate capacity and begin cross-training for future Asian production options.
The result? Units were completed on time, within budget, and were shipped by sea - avoiding expensive air freight.
Mechatronic expansion isn’t easy
This kind of flexibility to scale at short notice just isn’t possible for most OEMs running their own manufacturing operations. For these companies, outsourcing is an obvious route to explore.
But while many EMS companies claim they can do what’s required for a large mechatronic project, few can. We recommend some further checks are carried out to make sure they really can.
So, how do you know who can help?
Six capabilities you need to look for in a mechatronics partner
1. End-to-end manufacturing support
Modern mechatronic products combine mechanics, micro-electronics, sensors, wiring, and embedded software. You need a partner who can handle every layer, from PCBAs and plastic injection moulding to precision machining and software integration.
A vertically integrated EMS provider keeps everything in sync, reduces handover time between different suppliers, and shortens lead times.
Here’s why end-to-end outsourcing makes sense
2. Testing that finds the faults others miss
Electromechanical assemblies hide complex failure risks - cracked solder joints, sensor drift, torque inconsistencies, or feedback loop issues. Your EMS partner should design testing in from the start and apply real-world simulation, X-ray, and diagnostics to catch what visual checks can’t. Smart testing prevents recalls, accelerates launch, and protects your brand.
Learn how to overcome mechatronic testing challenges.
3. Logistics that deliver
You’ve built a product that works. Now it needs to survive the journey. From custom foam inserts to shock-absorbing crates, a good EMS partner ensures your assembly ships safely, no matter the size, weight, or fragility. They’ll also handle regulatory compliance, optimise shipping routes, and help reduce costs through smarter logistics planning.
See what can go wrong with mechatronics logistics.
4. DfX built into every stage
Design for Excellence is about more than making something manufacturable. It’s about making it testable, serviceable, cost-efficient, and scalable. EMS partners with strong DfX capabilities feed back on everything from board layout to material availability - helping you avoid late-stage design changes and production delays.
Read how DfX strengthens mechatronics projects.
5. Consider factory transfer potential
In a factory transfer, an OEM hands over full responsibility of the operational site to a manufacturing partner. The EMS provider takes on the people, assets, and processes, then upgrades and integrates the site into its own systems. This keeps production running, preserves knowledge, and delivers faster scale-up without the disruption of starting over. If you need to de-risk your mechatronic growth process this is an option you should definitely consider.
Explore how factory transfers can drive faster growth.
6. Project control should hold it all together
Complex mechatronics programs often involve multiple product variants, long-lead-time parts, specialist tooling, and multiple workstreams (mechanical, electrical ad software). Coordinating these across sites and teams demands tight project control and a strong digital backbone.
ESCATEC’s MES (Manufacturing Execution System) tracks production readiness, supplier status, tooling availability, and yield metrics in real time. Risk assessments, buffer strategies, and contingency plans are baked into every client’s NPI process—from project planning to full ramp-up
Steven Waterson, Director Business Development, ESCATEC
Don’t just outsource - outpartner
When your customers demand more, you need a partner who understands what’s at stake - and can move at the pace you can’t. ESCATEC’s global footprint, engineering depth, and operational agility make us more than a supplier. We’re your growth enablement partner.
Whether you're scaling up, transferring projects, or moving into new markets, we’re already building the runway.
