Calpak USA PPT

Design, Engineering, & Manufacturing Solutions

Who we are

At Calpak USA we don’t just strive for perfection, we make it a reality for our customers. With over forty (40) years of experience in our engineering design and manufacturing team, there is no project too niche or too big that we cannot tackle. Having served, but not limited to, the aerospace and aviation, automotive, commercial, communications, consumer, defense and military, green and renewable energy, industrial, lighting, medical, and transportation industries, there is no area that does not fall under our expertise.

It has been Calpak USA’s mission to be an integral player in bringing contract manufacturing back to the United States of America. With an ever-growing cost competitiveness of offshore solutions, it has become our duty to become even more cost competitive for bothour domestic and non-domestic customers, without any sacrifice to quality and reliability whatsoever. Offshore solutions cannot match our unprecedented level of customer service and quality control. Our continuously expanding list of industry specific certifications proves testament to this. Quality control and cost-effective solutions are and will always remain our top priority. Furthermore, Calpak USA is both a small and minority owned business. Calpak USA, has had its home in Southern California since 1978.

Designed. Engineered. Manufactured.

The Vision

Our mission at Calpak USA, Inc. is to take a leadership role for a new generation of American manufacturing. We are making “Going Onshore” our blueprint for the future. We provide entrepreneurs, as well as established companies, a competitive resource toadvance products from prototype to production with best in class manufacturing processes that are a step closer to zero-defect manufacturing.

We accomplish this with data analytics, quality controls, and superior engineering. Our production process utilizes root-cause analysis. Simply put, we have an early warning system that highlights potential defects, not only outside of specifications, but withinspecifications as well, and we are quick to propose solutions.

We accept the challenge of educating customers about the Cost of Poor Quality (COPQ) from offshore manufacturing and making “Made in America” the only solution. This will secure jobs for our employees, create new jobs, and stimulate the US economy.

We are working to make sure the next five years are momentous. The theme for success will be creative training of customers and employees, forethought applied to supply-chain issues and strong ethical and creative leadership.

Our success will derive from technical expertise in our niche, high quality work, and strong customer relationships that we nurture through end-to-end services. We will maintain a positive P&L with a strong pipeline of sales. We will maintain a good reputation with our customers, suppliers and employees. We will continue to compete successfully and be on par with companies many times our own size. Our goal is to inspire the rest of the industry – regardless of our size.


Industries Served

Calpak USA has delivered some of the most technical designs and assemblies for a wide array of products and projects – from simple consumer low content/high volume production to highly complex high content/low volume defense systems. Calpak USA has expertise in the following industries:

Industries

• Aerospace & Aviation• Commercial• Communications• Consumer – IoT, Home Automation, Wearable Technology, etc.• Defense & Military• Green & Renewable Energy – Energy Management/Harvesting• Industrial• LED Lighting• Medical• Transportation & Automotive


Our Core

At Calpak USA we adhere to a defined process to achieve a common goal. Phase 1 is the evolution of a relationship between Calpak and our clients with a common cause - Design. In Phase 2 information is exchanged freely, openly, and confidently leading to -Engineer. For Phase 3 both parties agree on all elements of the design, product has been engineered and we proceed to -Manufacture. Complete all three and you will have - Designed. Engineered. Manufactured.

1. Design (verb) - do or plan (something) with a specific purpose or intention in mind.• decide upon the look and function of (a circuit board, assembly, or electronic product), typically by having detailed • specifications and drawings of the product.

2. Engineer (verb) - design and build (a machine or product).

3. Manufacture (verb) - make (something) on a large scale using machinery and technology• to cause (something new) to exist• to cause (a particular situation) to exist• to produce (something new, such as a work of art) by using your talents and imagination• invent or fabricate


The Process


Design

Specification & Schematics (ORCAD & ALLEGRO)

PCB Layout (PADS & Altium)

Software

Design for Manufacturability

Assembly Drawings

Fabrication Drawings

Engineer

Fast Turn

Expertise

Multi-Material

Testing

Manufacture

Prototypes

Production

High Volume/Low Content

Low Volume/High Content

High Volume/High Content

Full Turn Key

Kitting

Pack out

Materials Management

Product & Project Support

Design, Engineering, & Software Services

Calpak USA offers comprehensive design, engineering, and software services for your product or project needs. Our engineering design

solutions can help you with your next project or help get your new idea or product off the ground and into the market place. We can help

you with initial conception, offering practical and real-world advice and solutions throughout the entire design cycle and also incorporate

DFM (Design for Manufacture) to help improve the manufacturing efficiency of the assembly and reduce the overall cost of your product.

Design & Engineering

• Conceptual design and development for your project or product

• Full project or product specification and documentation

• Schematic research and capture services

• Use of industry standard PCB CAD program(s) for board layout

• Design for manufacturability

• Total software design and development including firmware, PC or Mac programs, and mobile applications. Familiarity and experience

with a plethora of microprocessor, FPGA, and logic device manufacturers.

• Test kit development and manufacture to aid project or product verification and validation

• Prototype and First Article Review


Printed Circuit Board (PCB) Design Layout

Calpak USA is well-seasoned experts in PCB Design and Layout with a remarkable reputation in, but not limited to: analog, high speed digital, mixed-signal, electro-magnetic, high power and charging, RF, and wireless systems. We design printed circuit boards up to high layer counts (up to 32 layers), of rigid, and flex-rigid printed circuit boards. Whether the project or product entails short lead-time, constraint-driven requirements, routing, or basic I/O, our highly qualified engineers and technical staff have the expertise to deliver extensive designs that are top quality, well-managed, and most importantly, on-time and cost effective.

PCB Design Services

• Schematic capture• Surface mount or through hole designs• Unusual PCB shapes• Assembly and fabrication drawings production• Board layout from a customer supplied schematic diagram• Reverse engineering• Controlled impedance (single and differential) designs• Specialized layout for RF and wireless designs• High Speed Backplane and Mid-plane Designs of Micro BGA / Micro via/ Blind & Buried Vias• Multi-layer boards, split ground planes, differential pairs, high speed rules• Routing per trace/space, keep-outs, and clearance rules specified by customer• Component re-sequencing based on physical layout, and reverse annotation to schematic• DFT audit, test point placement, test probe clearance per customer specification, testability reports


Printed Circuit Board (PCB) Fabrication

Calpak USA offers a wide array of PCB fabrication capabilities.


Design & Test

• 2 mil Trace Width• 3 mil Air Gap• IPC Class 2 / IPC Class 3• Flying Probe Net List Test• Differential Impedance• TDR Testing• Automatic Optical Inspection

Lamination

• 1 to 32 Layers• Vacuum Lamination• Sequential Lamination

Plating

• Conductive Via Fill• Non-Conductive Via Fill• Plated Edges• Plated Radii (Castellation)• Plated Milling Cutouts• Hard Gold Body• Soft Bondable Gold• Immersion Gold• Hard Gold• Immersion Silver• HASL Standard• HASL Lead Free (ROHS)• Entek (OSP)

Drill & Rout

• Counter Sinks / Counter Bores• Scoring / Rout & Retain• Laser Route• Blind Vias / Buried Vias• Stacked Vias

Materials

• Flex & Rigid Flex• Kapton & Non Kapton• RF & High Speed Materials• FR4• High Tg / Rodgers• Mix Materials / FR4 Teflon• Metal Back Boards• Heavy Cu 6 oz. Finish

Printed Circuit Board (PCB) Assembly

Calpak USA’s specialization lies in populating through-hole, surface mount, & mixed technology PCB’s, along with BGA components using our state-of-the-art PCB assembly equipment such as high-speed pick and place machines, multi-zone reflow ovens, and dual wave/chip solder machines. Through efficient component procurement & supply chain management, Calpak USA is able to deliver cost effective PCB assembly solutions with quick turnaround times.

PCB Assembly capabilities include but not limited to:


PCB Assembly

• Surface Mount (SMT)• Through Hole• BGA (Ball Grid Array)• Mixed Technologies• Single, Double, Multi-Layer, Rigid, Flex Assembly• AOI “Automated Optical Inspection & X-Ray• Manual Microscope Inspection• Automated and Hand Placement• Each line can pick and place up to 8 components / second• Multiple lines enables us to place over 400,000

components per shit• Have ability to quickly add more lines to our setup

Wire, Cable & Mechanical Assembly

As a natural progression of manufacturing services offered, Calpak USA has core competencies in wire, cables harness, mechanicalassemblies, panel assemblies and box builds. Whether it be prototyping or production, rest assured, all work performed by Calpak USA will adhere to strictly to quality control and on time delivery.

Our Wire, Cables & Mechanical Assembly capabilities include but not limited to:


Cable, Wire, & Mechanical

• Custom Cable, Wire, & Harness Assembly• Box Builds• Enclosure & Panel Assembly• Mechanical Parts Fabrication• Other Electro-Mechanical Parts Fabrication

Materials Procurement

Calpak USA strives to be a “one-stop-shop” for customers. From engineering services, bill of materials procurement and to assembly. Calpak USA offers:


Inventory

• In-house stock: common values, tolerances and sizes of passive components• Calpak’s global network with access to global stock• Strong alliances with key component distributors and manufacturers• Electronic links to our key suppliers and their inventories• Prototype quantities welcome• Quick-turn procurement available• Large volume discounts• Warehousing capabilities for your materials• Buying power• Supply Chain Management• Complete Turn-Key Solution

Overview of General Capabilities

Calpak USA offers a wide array of service capabilities. Some of those capabilities are:


Hardware Design

• Audio• Battery Charging• Design for RoHS Compliance• Ethernet• FPGA Design• Digital, Analog, & Mix Circuit• LED Lighting• Impedance Control• Motor Control• Power Supply• RF• USB• Video

Mechanical Design

• Enclosure Design• Industrial & Rugged Design• Industrial Packaging• 3D Modeling• Plastic Injection• Materials Selection• Metal & Plastic Part Design

Project Management

• Turnkey Solutions• Component Purchasing• Patents• FCC Certifications• Problem Diagnostics• Product Cost Estimating• Product Test & Quality • Project Management• Technical Marketing• UL, CE & CSA Certifications

System Level Design

• Analog Simulation• RF Simulation• Block Level System Design• Communication Systems

Software Design

• ARM• Board Bring Up (BBU)• Boot Loaders• C / C++• Device Drivers• DSP Algorithms• Signal Processing• Firmware Development• Embedded GUI’s• FPGA

Prototype & Manufacturing

• Design for Manufacturability• Documented Procedures• Manufacturing Services• Prototype Assembly• Testing• Test Fixtures• Low, Medium, High Production Runs• Scheduled Deliveries• Sheet Metal Production• Panel & Enclosure Assembly, Box Builds• Cable & Wire Assembly• Plastic Injection• Die Cast

Software Design

• MCU Firmware• Android• Linux• iOS• Windows• PC Software• RTOS• PLC• Web Based User Interface• Database

Wireless Design

• Antenna Design• Bluetooth• Cellular• GPS• Wi-Fi• Zigbee

Quality

• AS9100C• ISO:9001• Process FMEA• AS9102 First Article• Lean Six Sigma• TQM

Advantages of Calpak USA

Calpak USA makes it a point to endeavor beyond the competition so customers can reach their goals.

Benefits of Calpak USA

• Services delivered at globally competitive price• Made in USA – Calpak USA is located in Southern California• Unwavering commitment to Quality – no compromises• 100% Quality and Timed Deliveries – proven results• Labor & Ecology Sensitivity• Strategic Partnerships with Suppliers• In-House design, engineering, and manufacturing = streamlined supply chain• Minimized Logistical Costs• Proven experience, expertise, and capabilities in all industries• Able to assist customers in any phase of concept-to-market• Proactive, interactive, and professional • Protection of Intellectual Property• “Quick-to-Market” approach• Customer oriented


Disadvantages of Competition & Overseas

Calpak USA makes it a point to endeavor beyond the competition so customers can reach their goals.

Offshore Competition

• Cost of Poor Quality• Counterfeit Components• Recalls• Rework• Disposals• Disregard for Ecology – Carbon Footprint• Disregard for Humanity – Slave Labor• Disregard for Intellectual Property – Product Knock Off• Extensive Travel• Communication Barriers• Logistics Nightmare• Delay to Market• Payment in Advance – no customer service or warranty• All things considered – not really less expensive


Certifications, Registrations, Partnerships

Calpak USA has the tools to prove its commitment to customers. Calpak USA make it a top priority to remain current with industryspecific leading quality certifications, management systems, and strategic partnerships.


Quality Certifications

• AS9100C• ISO:9001• ISO:13485 (pending)

• NADCAP (pending)

Ownership Diversity

• SBE (Small Business Enterprise)• MBE (Minority Business Enterprise)

Other Registrations

• CAGE • RoHS• IPC (pending)

• ITAR (pending)

• EAR (pending)

Partnerships

• Microchip Technologies• Digi-Key• Atmel (pending)

Quality

Calpak USA will consistently provide products and services that meet or exceed the requirements and expectations of our customers. We will actively and continuously pursue ever improving quality through programs that enable each employee to do their job right the first time and every time.


Management System and Quality System Overview

Customers

Requirements

Customers

Satisfaction

DO(Product

Realization)

Check(Measurement

Analysis and C.I.)

Plan(Resource

Management)

Act(ManagementResponsibility)

Input Product Output

Continuous Improvement of the Management System

General Information


Headquarters

13750 Prairie Ave.Hawthorne, CA 90250T: (310) 937-7335F: (310) 937-7219E: [email protected]

Identifier Codes

• D&B: 161585620• CAGE: 750L8

Year Established

1978

Mailing Address

2110 Artesia Blvd. Ste. B202Redondo Beach, CA 90278T: (310) 937-7335F: (310) 937-7219

Corporation Type

C

Federal TIN

EIN: 95-4872221

NAICS

• 334412• 334418• 334419• 335999• 339999• 541330

SIC

• 3672-02• 3679-01• 3999-03• 4813-02• 8742-13

Documents

Calpak USA PPT