IntelliDesign is a design
and manufacturing company.

We work with progressive organisations to create game changing products together.

Electronic Manufacturing Services at IntelliDesign

IntelliDesign is a manufacturing partner that can create and deliver products at scale. We specialise in the design and manufacture of electronic products for customers in all industries from medical and mining through to the defence and aerospace industries. It’s not just a circuit board assembly service but a complete turn-key product assembly solution from supply chain management through to product assembly and factory acceptance testing.

Specialisation

Our products are generally technically challenging, mission critical and can be used in physically demanding environments. These applications are backed by full traceability of material procurement and our assembly steps using our custom-built Enterprise Resource Planning (ERP) and data management system.

All the products we manufacture go through a new product introduction phase which makes sure conforming product is delivered on time. This applies equally to product coming through our product design service as well as contract manufacturing.

Production Team

The production team at IntelliDesign consists of about 80 highly trained staff. Our people bring individual strengths to embrace challenges as a collaborative team. Diversity of talent and depth of experience combine to drive innovation and mitigate risk. Every day at IntelliDesign interdisciplinary clusters of people can be seen picking apart and solving shared challenges with rigor and imagination.

IntelliDesign invests in long-lasting partnerships with our customers, and our success is tied directly to their success.

Electronics Assembly

Hundreds of thousands of components are placed every day on three fully automated surface mount assembly lines which cater for volume, high component count and prototype assemblies.

Common characteristics of the boards we assemble:

Rigid | flex-rigid | layers 22+
Simple | high complexity (1000+ part) 2-sided SMT
RoHS | leaded
Low volume/high complexity (20 units/month) | medium volume (1000 units/week)
0.25mm pitch BGA and CSP
Thru hole, press fit, edge mount
Automated selective soldering
Automated jet dispensed (selective) conformal coating
Automated board wash

Testing

We test every board and every product we ship. For some customers, this may involve subjecting each device to thermal and vibration testing.

Some of the tools we use include:

End Product Assembly

We install 80% of the boards we manufacture into the end-product. Plastics, precision metal parts, cable harnesses, optical elements, pneumatics, electromechanical components are just some of the items which come together along our lean assembly lines.

Certainty and flexibility are important to our customers. Flexibility to adapt to changing situations, to scale, to undertake unique inline tests, to modify schedules. All underscored by certainty of delivery.

Supply Chain and Lifecycle

We understand that supply chain management is critical to our shared success. As part of our dual ISO9001, AS9100D certification, we audit and support the ongoing development of our custom part suppliers. This ensures we maintain a mature capability to deliver demanding assemblies flowing down to customer requirements.

IntelliDesign orders hundreds of components and custom parts every day and maintains 100% traceability. Our proprietary Enterprise Resource Planning and quality management system tracks every step, of every process, for every product from cradle to customer and sometimes beyond. IntelliDesign is certified to ISO14001 for Environmental Management.

We proactively manage component-level obsolescence challenges for our customers. We assist our defence customers with the sourcing and validation of historical parts which have been end-of-life for many years.

Service and Repair

Our customers deploy the products we build into extremely hostile and physically demanding environments. IntelliDesign’s dedicated service team provides rapid turnaround back-to-base repair and support services for our customers.

Critically, the observations and learnings from the service team are fed back into design and engineering, embedding continuous improvement and informing the design decisions of our customers’ next generation of products.

Certification

IntelliDesign is certified to design and manufacture under AS9100D, ISO9001, is IECEx QAR registered, and has IPC class 3 production capabilities. We have also been manufacturing a precision vacuum pump used for IVF for Cook Medical for over 20 years and a Tilt Sensor for Topcon for a similar period.

We have a test lab with environmental chambers and vibration tables for testing our products under these extreme conditions.

Engineering Support

Our manufacturing facility is a short walk from our design and engineering office, so designing products that are suitable for efficient and economical manufacturing at scale, is one of our competitive advantages at IntelliDesign. The engineering team provides ongoing support for our production teams, including test jigs, process improvements, issue resolution, maintenance and improvements in productivity.

Operations Management

IntelliDesign has a professional operations management team consisting of specialists in procurement, stock control, production engineering, planning and logistics. This team manages the wide variety of products that we manufacture every day to ensure that we are achieving the quality standards and meeting the client’s delivery schedules.