Short answer: An energy systems provider supplying electronics for demanding industrial environments needed PCB assemblies that run continuously for years in harsh conditions, so manufacturing quality and long-term component availability were critical. Comtec Labs strengthened the robustness of the boards, took over component lifecycle management and set up stable, repeatable production processes with particular attention to soldering quality, testing and long-term sourcing. The result: field failure rates fell by over 60 %, there were no unplanned production stoppages over several years, and the customer gained lasting confidence in its electronics supply chain.
An energy systems provider supplying electronics for demanding industrial environments required highly reliable PCB assemblies with long operational lifetimes. Their products were expected to perform continuously, often in harsh conditions, making manufacturing quality and component availability critical.
Comtec Labs supported the customer by strengthening PCB robustness, managing component lifecycles, and implementing stable, repeatable production processes. Emphasis was placed on soldering quality, testing, and long-term sourcing strategies.
HIGHLIGHTS
Field failure rates reduced by over 60%
Zero unplanned production stoppages over multiple years
As a result, the customer achieved improved system reliability and long-term confidence in their electronics supply chain.
Key facts
- Field failure rates fell by over 60 % after the robustness and process work.
- No unplanned production stoppages over multiple years of production.
- Component lifecycles are managed proactively so that a long-life product stays buildable.
- Soldering quality, testing and long-term sourcing were the levers – not short-term unit price.
Frequently asked questions
Can Comtec Labs manufacture PCB assemblies for products with a long service life?
Yes. For long-life products we review the design for robustness, select components with a stable lifecycle status and define the soldering, cleaning and test process so that it can be repeated identically batch after batch.
How do you handle component obsolescence in energy electronics?
We track the lifecycle status of every active component in the BOM, flag end-of-life notices early, and propose qualified alternates or last-time buys before a part becomes a production stop.
What testing do you do for high-reliability energy electronics?
Automated optical inspection on every board, functional test against the customer's specification, and X-ray for hidden joints where the design calls for it.
Do you support both prototyping and series production for energy systems?
Yes. The same team takes a design from prototypes through pilot batches to series production in Vaasa, so process knowledge and traceability stay in one place.
Ready to reduce PCB surprises?
Comtec Labs offers a full suite of services to streamline your workflow:
PCB design service
PCB prototyping service
PCB component sourcing
PCB component assembly
PCB testing service
PCB repair and modifications
Printed circuit board production
PCB mass production