BUILD

Calpak USA offers prototype assembly for 1 to 100 boards with quick-turn delivery, production assembly supporting volumes up to 10 million units per year, and full turnkey assembly where we handle everything from PCB fabrication and component procurement through final test and shipping. We assemble using surface mount technology, through-hole insertion, and mixed technology processes, all to IPC Class 2 or Class 3 workmanship standards depending on your application requirements.

In consigned assembly, you supply the bare boards and components, and Calpak USA performs the assembly, soldering, inspection, and testing. In turnkey assembly, Calpak USA manages the entire process — we fabricate or procure bare boards, source all components through authorized distributors, assemble the boards, and deliver finished tested units. Turnkey assembly simplifies your supply chain to a single point of contact and is ideal for customers who want to focus on design and sales rather than component procurement and logistics.

Calpak USA offers quick-turn prototype assembly with turnaround times starting at 5 business days for consigned builds where all parts and boards are supplied. Turnkey prototype builds typically take 2 to 3 weeks depending on component lead times. For urgent programs, we offer expedited scheduling with priority placement on our SMT and through-hole lines. Every prototype build uses the same equipment and IPC workmanship standards as production, so your prototype results directly predict production yields.

Yes. Calpak USA fabricates multi-layer printed circuit boards up to 30 layers using advanced materials including FR-4, Rogers, polyimide, and metal-core substrates. Our fabrication capabilities include controlled impedance, blind and buried vias, HDI microvias, rigid-flex construction, and heavy copper for power applications. Offering both fabrication and assembly from our Hawthorne, California facility eliminates shipping delays between vendors and ensures that bare board quality is verified before assembly begins.

Calpak USA holds AS9100 Rev. D certification for aerospace quality management, ISO 9001 certification for general quality management, ITAR registration for defense and export-controlled programs, and ANSI/ESD S20.20 certification for electrostatic discharge control. Our IPC-certified operators and inspectors assemble to J-STD-001 soldering standards in both IPC Class 2 and Class 3. These certifications are maintained through annual third-party audits and qualify Calpak USA for aerospace, defense, medical, and commercial manufacturing programs.

Yes. Calpak USA provides complete box build and systems integration services, assembling finished products that include PCB assemblies, wire harnesses, mechanical enclosures, displays, connectors, and packaging. Our team manages the full integration process from sub-assembly through final system-level functional testing. This is ideal for customers who need a single manufacturer to deliver shelf-ready or field-ready products rather than individual circuit boards.