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Mechatronics & Electromechanical Assembly

ESCATEC provides mechatronics and electro-mechanical assembly services for OEMs developing complex electronic and mechanical systems, from integrated sub-assemblies through to complete machines and industrial equipment. Our scope includes PCBAs, mechanical components, wiring harnesses, control cabinets, and software-controlled systems.

Mechatronics Assembly with ESCATEC

ESCATEC supports everything from small benchtop products and sub-assemblies through to large-format electro-mechanical machines, integrating electronics, mechanical components, sensors, pneumatics, and automation technologies.

By combining electronics manufacturing expertise with mechanical integration and supply chain management, ESCATEC helps OEMs scale production of complex machines while maintaining quality, traceability, and configuration control.

Key facts at a glance

Complex electro-mechanical assembly and integrated machine builds.
Control cabinet assembly and rack systems.
Wiring looms, cable harnesses, and electrical panel wiring.
Precision mechanical integration including fabricated and machined parts.
Software loading, verification, and revision control.
Mechanical, pneumatic, and electrical system testing.

Why choose ESCATEC for your mechatronics assembly needs?

ESCATEC supports everything from sub-assemblies and benchtop products through to large electro-mechanical machines.

Unlike many manufacturing partners that specialise in either electronics or mechanical assembly, ESCATEC integrates electronics manufacturing, mechanical assembly, electrical integration, and system-level testing within a single manufacturing environment.

For OEMs developing complex machines, this means mechanical, electrical, electronics, and test requirements can be planned together, with supply chain and production engineering teams involved early in the process.

The result is fewer hand-offs between suppliers, reduced integration risk, and more consistent production for complex electro-mechanical systems.

OUR DESIGN, DEVELOPMENT, AND MANUFACTURING SERVICES

We offer comprehensive EMS services for OEMs looking to scale their business by outsourcing design & manufacturing.

Design, Development & DfX

Engineering support to improve manufacturability, testability, and  production readiness.

New Product Introduction

Structured NPI to move products from development into controlled production.

Manufacturing Capabilities

Prototyping, PCBA, microelectronics, box build assembly, mechatronics, machining, and injection moulding.

Test Solutions and QA

Test approaches to support verification and quality control during manufacturing.

Supply Chain Management

Procurement and supply chain coordination for build continuity.

Value-Added Post-Production Services

Servicing, repair, lifecycle management,  and logistics.

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Design & Development

New Product Introduction

Supply Chain Management

Plastic Injection Moulding

Test Solutions

Post Production

ESCATEC’s mechatronics capabilities

ESCATEC offers a wide range of mechatronics solutions and supply chain experience covering mechanical integration, electrical assembly, automation technologies, and system-level testing:

Product design

Reverse engineering

DfX

Industrialisation

Fabricated parts

Machined parts

Plastic parts

Pneumatics

Machine vision

Sensor technology

Robotics and automation

PCBA integration

Wiring looms and harnesses

Energy chains and cable routing

Control cabinet assembly

Heat management and ventilation

High voltage installation and test

Display units

Software load and test

Custom system integration

Postponement manufacturing

Configure-to-order manufacturing

Direct ship fulfilment

Achieving scalable multi-market expansion

ESCATEC collaborated with a global leader specialising in material handling solutions to overcome production challenges and achieve operational excellence. Our tailored approach and scalable solutions ensured that the client met tight timelines and exceeded performance expectations, resulting in a transformative outsourcing model that bolstered the client’s global market position.

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Achieving scalable multi-market expansion

How does ESCATEC manufacture complex electro-mechanical systems?

ESCATEC produces and ships many complex electro-mechanical assemblies each week, often including a similar number of individual parts to a PCB assembly. With so many moving parts that demand skill, precision, accuracy, and consistency, we refer to these assemblies as machines rather than products or units.

Producing electro-mechanical systems of this complexity requires careful control of mechanical tolerances, supply chain quality, electrical integration, and configuration management.

Precision electro-mechanical assembly

ESCATEC produces complex electro-mechanical assemblies each week, often containing a similar number of individual parts to a PCB assembly. With many moving components, these builds require careful control of engineering tolerances and the use of mechanical gauges and precision tools. Our experience also extends to testing mechanical and pneumatic assemblies to ensure reliable operation.

Lean manufacturing for complex assemblies

Interactive electronic documentation, multi-language work instructions, and robust variant management controls support ESCATEC’s quality-controlled production lines. Lean assembly cells are typically resourced by between two and ten operators, depending on live customer demand. Line-side KanBan replenishment and barcode tracking provide real-time operational visibility and efficient material flow.

Electrical assembly & control cabinets

Many mechatronic assemblies require wire or cable interconnections between boards and sub-assemblies, including cable looms, harnesses, and point-to-point wiring. ESCATEC also undertakes electrical wiring of switch panels, rack systems, and sophisticated control cabinets, including continuity, high-voltage flash, and PAT testing.

Software control & revision traceability

Software upload, verification, and execution are carried out within ESCATEC’s robust revision control system. This ensures accurate configuration management during production. Historical records of both hardware and software revisions can be provided to maintain full traceability for the products we build.

Cable assemblies & wiring looms

ESCATEC manufactures cable assemblies ranging from simple point-to-point wiring to complex multi-component wiring looms. We process cable sizes from 36AWG to 6AWG for use in demanding environments, including medical, surgical, and high-end audio systems. Whether producing individual cables or complete harnesses with connectors, switches, and fuses, our focus is on accuracy and repeatable quality.

Together, these capabilities allow ESCATEC to manufacture complex electro-mechanical systems ranging from small benchtop devices to large integrated machines.

Each programme is supported by a dedicated Key Account Manager who acts as the primary interface between the customer and ESCATEC’s engineering, supply chain, and production teams. This encourages direct engineer-to-engineer communication and ensures materials, machine settings, PFMEAs, and quality plans are managed effectively throughout production.

What makes ESCATEC’s mechatronics assembly different?

ESCATEC combines electronics manufacturing, mechanical integration, supply chain management, and system testing within a single manufacturing environment.

This allows OEMs to develop complex machines without needing to coordinate multiple suppliers across mechanical, electronic, and electrical disciplines.

With expertise in configure-to-order manufacturing, postponement manufacturing, and flexible production lines, ESCATEC provides a turnkey manufacturing environment for complex mechatronic systems.

What industries and product types does ESCATEC support?

ESCATEC supports OEM programmes across the Industrial, Medical, and Transportation sectors.

Typical products include:

industrial automation systems
control and monitoring equipment
integrated machine platforms
modular robotic sub-assemblies
instrumentation systems
complex electro-mechanical devices

These products often require precise integration of electronics, mechanical components, wiring systems, and control software.

What other capabilities and supply scope can ESCATEC provide?

ESCATEC supports programmes from prototype and pilot builds through to higher-volume production.

Our wider scope includes:

product design and DfX support
supply chain management
industrialisation and NPI
mechanical and electronic component sourcing
system integration and test
configure-to-order manufacturing
logistics and direct ship fulfilment

Whether your product is a benchtop device, rack system, or complex mechatronic machine, ESCATEC provides a complete manufacturing solution.

READY TO START YOUR MECHATRONICS PROJECT WITH ESCATEC?

Talk to ESCATEC about your mechatronics or electro-mechanical assembly requirements, including product scope, mechanical content, electronics integration, test requirements, and expected production volumes.

Our engineering and manufacturing teams can help define the right DfX, NPI, supply chain, and manufacturing approach early in the project.

TALK TO OUR TEAM

Mechatronics Assembly FAQs

What is mechatronics assembly?

Mechatronics assembly integrates mechanical components, electronics, electrical systems, and software into a single product or machine.

Can ESCATEC build complete electro-mechanical machines?

Yes. ESCATEC supports builds ranging from sub-assemblies and benchtop products through to large electro-mechanical machines and control systems.

Does ESCATEC integrate wiring harnesses and cable systems?

Yes. ESCATEC produces simple cables, complex wiring looms, and integrated cable routing systems used in electro-mechanical products.

Can ESCATEC support control cabinets and rack systems?

Yes. ESCATEC builds control cabinets, rack systems, and electrical panels, including wiring, mechanical modifications, and electrical testing.

Does ESCATEC support prototypes as well as production?

Yes. ESCATEC supports prototype builds, pilot production, and higher-volume manufacturing, depending on the complexity and requirements of the programme.

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ESCATEC's manufacturing capabilities are complemented by enhanced support services for our clients, such as design and development support, test solutions, sophisticated supply chain management, postponement manufacturing and direct-ship outbound logistics.

PCB Assembly

We support customers from the prototype and industrialisation stages, through to the ongoing manufacture of complex, multi-technology PCBAs, in low, medium and high volumes.

Box Build Assembly

We're experts in complex sub-assemblies and finished, tested, products. We offer turnkey electronics, mechatronics, cabinet assembly, system integration & test solutions.

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Mechatronics

ESCATEC offers a wide range of mechatronics solutions and supply chain experience - everything from ‘benchtop’ products through to ‘large format’ electro-mechanical machines.

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Machining

From simple CNC turned components to elaborate CNC milled assemblies, we cater to diverse sectors, including industrial electronic, transportation and medical device manufacturing.

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Test Solutions

A proven method of electronics manufacturing defect detection and prevention, flying probe testing also eliminates the requirement for dedicated fixturing.

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Plastic Injection Moulding

At ESCATEC we use cutting-edge technology and equipment, to ensure that every injection moulding project we undertake meets the highest standards of quality and precision.

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Microelectronics

Our experienced teams design, develop and manufacture high performance LED, laser, and lighting solutions. We ensure micro-optic needs for complex MOEMS products are met and delivered.

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Design & Development

We specialise in electronics, software, mechanical, and system design and development. Following Design for eXcellence (DfX), Design for Manufacture (DFM), and VA/VE best practices, we turn your ideas into market-ready products.

New Product Introduction

Our unmatched NPI support is characterised by lean project management, comprehensive testing, robust supply chain management, and close collaboration with your teams to minimise risks, maximise results, and ensure product quality.

Supply Chain Management

With our established global supplier partnerships, our experienced procurement, SCM, and logistics teams can identify the best sourcing options based on your needs. We supply a vast range of products to various sectors reliably and cost-effectively.

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Prototyping

With our prototyping services, we are with you every step of the way, from schematic design to functional testing and validation. We work with you to refine your designs, creating a high-quality final product ready for mass production.

Post-production

Whether you’re launching a new and improved product iteration or extending the lifecycle of your existing in-market products, our post-production capabilities help to maximise profits and keep you ahead of the competition.

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