PCB Assembly. Custom Parts. Full NPI.
All Under One Roof.
Three manufacturing strengths, one vertically integrated partner.
Illuminious is a US-headquartered electronics manufacturer with production facilities in Shenzhen and Batam. We specialize in PCB/PCBA manufacturing, custom parts production (CNC, injection molding, die casting, sheet metal), and end-to-end NPI services from concept to mass production.
Configure it online, or send the job to an engineer. Online, you get a live supplier price, a published tier, or a specialist quotation within 24 hours on business days, depending on the service. Engineering review is free either way and comes before you pay.
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Three Manufacturing Strengths, One Partner
We are not just a PCB assembler. Illuminious delivers three equally powerful manufacturing capabilities, each backed by our own factories and our own engineers.
We fabricate and assemble printed circuit boards from simple 2-layer prototypes to complex 40-layer HDI stackups. Our vertically integrated PCB facility handles bare board fabrication, component sourcing, SMT/THT assembly, and comprehensive testing under one quality system. Prototype and volume schedules are stated in the official quote published after the free engineering review, and every board is built to IPC-A-610 Class 3 workmanship.
Layer Count
1–40 layers
Min Trace/Space
2.5mil / 3mil
SMT Lines
8 automated lines
Smallest Component
01005 (0.4×0.2mm)
Workmanship
IPC-A-610 Class 3
Prototype Lead Time
Stated in your official quote
PCB & PCBA
PCB & PCBA Manufacturing
Precision Electronics at Scale
Deep Dive
PCB & PCBA Manufacturing
Our PCB division handles the complete electronics manufacturing lifecycle — from bare board fabrication through component sourcing, SMT and through-hole assembly, to comprehensive testing and inspection. With 8 automated SMT lines capable of placing 01005 components at ±25 micron accuracy, we deliver IPC Class 3 workmanship for the most demanding applications in medical, automotive, and aerospace.
Every board undergoes 100% Automated Optical Inspection (AOI). Complex assemblies with BGA, QFN, and hidden joints receive 5DX X-ray inspection. We develop custom functional test (FCT) fixtures and In-Circuit Test (ICT) programs to verify every board meets your electrical specifications. Our component sourcing team manages over 350 audited suppliers, with qualified alternates proposed at review.
PCB Types We Manufacture
Deep Dive
Custom Parts Manufacturing
Beyond electronics, we manufacture the mechanical components that complete your product. Our custom parts division operates injection molding presses, 5-axis CNC machining centers, die casting cells, sheet metal fabrication lines, progressive stamping presses, and additive manufacturing systems — all in our own factories. This vertical integration means your enclosures, brackets, heat sinks, and structural components are manufactured alongside your PCBAs, eliminating the hand-offs between an electronics supplier and a separate mechanical one.
Injection Molding
Thermoplastic pellets are melted and injected under high pressure into precision steel molds. We use scientific (decoupled) molding principles — separating fill, pack, and hold phases — to achieve exceptional shot-to-shot consistency.
CNC Machining
Computer-controlled cutting tools remove material from solid billets with extreme precision. Our 5-axis machining centers handle complex geometries in aluminum, stainless steel, titanium, and engineering plastics with tolerances to ±0.01mm.
Die Casting
Molten metal is forced into reusable steel dies under high pressure, producing complex near-net-shape parts with excellent dimensional accuracy. Ideal for high-volume aluminum, zinc, and magnesium components.
Sheet Metal Fabrication
Flat metal sheets are laser-cut, CNC-punched, bent on press brakes, and welded into 3D structures. Our DFM-driven approach optimizes flat patterns for minimal material waste and efficient forming.
Metal Stamping
Progressive dies stamp metal strips at high speed, producing thousands of identical parts per hour. Each station in the die performs a different operation — blanking, piercing, forming, coining — in a single press stroke.
3D Printing (Additive)
Layer-by-layer material deposition creates complex geometries impossible with traditional manufacturing. We use SLA for smooth surfaces, SLS/MJF for functional prototypes, and FDM for concept models.
Deep Dive
NPI: Concept to Mass Production
Our structured New Product Introduction (NPI) process de-risks your product launch through five validated phases. Each phase has clear entry criteria, deliverables, and exit gates — ensuring nothing is left to chance. Your dedicated US-based project manager coordinates between your engineering team and our Shenzhen/Batam factories, providing weekly status reports and proactive risk management throughout the entire journey from concept to scale.
Kick-off & DFM/DFA Review
The NPI process begins with a formal kick-off meeting where our US and Asia engineering teams conduct a joint review of your complete design package. We provide comprehensive DFM/DFA/DFT feedback as part of the free engineering review, focusing on manufacturability, testability, component availability, and cost optimization opportunities.
Prototyping & EVT (Engineering Validation)
We rapidly produce and assemble the first prototypes to validate the core design. During Engineering Validation Testing (EVT), we focus on bringing up the board, testing key electrical functions, verifying mechanical fit, and catching fundamental design flaws before committing to tooling.
Tooling & DVT (Design Validation)
As the design matures, we initiate production tooling for plastics, metal parts, and test fixtures. Concurrently, we build a larger batch for Design Validation Testing (DVT), testing the product against its full specification list including environmental, reliability, and regulatory pre-compliance standards.
Pilot Run & PVT (Production Validation)
We conduct a pilot production run on the actual assembly line, at the batch size set in your project plan. This Production Validation Test (PVT) validates the entire manufacturing process: SMT programming, assembly workflow, quality checkpoints, packaging, and yield. Process capability studies (Cpk) confirm readiness for scale.
Golden Sample & Mass Production
Upon successful PVT completion, we present a 'Golden Sample' meeting all cosmetic, functional, and quality requirements for your final sign-off. This sample becomes the benchmark for all future production. Approval launches the transition to mass production with full quality control and continuous improvement.
US-Managed, Factory-Direct
Contracts signed in the US, protected by US law. You work with our Palo Alto team while our own factories handle production.
Dual-Factory Flexibility
Shenzhen for NPI speed and complexity. Batam FTZ for tariff-optimized mass production. Same quality system, your choice.
Vertically Integrated
PCB assembly, injection molding, CNC machining, box build, and fulfillment under one roof. No middlemen, no delays.
Global Manufacturing Footprint
We own and operate production facilities across three strategic locations, giving you the flexibility to optimize for speed, cost, or tariff avoidance.
Palo Alto, CA
Engineering & Management
Our US headquarters handles project management, DFM review, supply chain strategy, and client communication. All contracts are signed here under US law.
Shenzhen
NPI & Advanced Manufacturing
Rapid prototyping, complex PCBA, injection molding, CNC machining, and new product introduction. Eight SMT lines, with prototype schedules stated in the official quote.
Batam FTZ
Volume Production
Tariff-optimized mass production in a Free Trade Zone. Same equipment, same quality standards as Shenzhen, with significant cost advantages for volume.
Industries We Manufacture For
From FDA-regulated medical devices to high-reliability automotive electronics, our quality systems and certifications support the most demanding industry requirements.
Manufacturing Success Stories
See how we have helped hardware companies scale from prototype to millions of units.
View Case StudiesManufacturing Insights
Expert articles on DFM, supply chain strategy, and electronics manufacturing best practices.
Read Our BlogHardware Startup? We Built Our Factory for You.
Our Startups Program gives you direct factory access with no MOQ, dedicated engineering support, and one team from prototype to mass production.
Explore Startups ProgramReady to Manufacture?
Send us your Gerber files, BOM, or 3D CAD models. Our engineers will provide a detailed DFM review and manufacturing quotation within 24 hours on business days. An engineer reviews every order.
Three lead-time tiers, each with its trade on the line: Economy lengthens the quoted target range and takes a discount line; Standard is the quoted target range at the quoted price; Express shortens it and adds an expedite line. You see the line before you commit, and every range is a target, not a promise.