High Speed Surface mount (SMT)
Through-hole (PTH)
Designated Prototype SMT line
AOI
Rigid, Flex, FR-4, metal and hybrid
Single or double-sided, multiple layers
Single board or panelization
RoHS-compliant and tin-lead options
.webp)
Electronics Contract Manufacturing
ABOUT US
Electronics Contract Manufacturing Services
Sunburst Electronics is a full-service provider of custom electronics contract manufacturing services, proudly serving industries such as medical, defense, aerospace, transportation, industrial controls, and oil & gas. We specialize in printed circuit board assembly (PCBA), box builds, cable assembly and integrated High- reliability electronics systems for mission-critical applications
We provide complete or partial product assembly, testing, and full lifecycle supply chain management. With a commitment to precision, quality and unmatched customer service, Sunburst Electronics is your trusted partner for end-to-end manufacturing excellence.
.webp)
Founded in
1976
1976
KanBan Programs
ESD Control Program
IPC Trained
Staff
Staff
Fully Integrated MRP System
Global Customer Base
Our Programs
Quote now
New Product Introduction (NPI)
Accelerate your time-to-market with dedicated prototype lines, design-for-manufacturability reviews, and rapid iteration cycles.
.webp)
Printed Circuit Board Assembly (PCBA)
High-speed SMT, through-hole, BGA, and hybrid assemblies. ROHS compliant and tin-lead options with full AOI inspection.
Electro-Mechanical Box Builds
Complete system integration including enclosures, wiring harnesses, and full functional testing for rugged environments.
Comprehensive Engineering Services
DFM/DFT analysis, test fixture development, process engineering, and supply chain optimization for your product lifecycle.
.webp)
Product Acceleration
Compress your development cycle. Our NPI team partners from day one to eliminate rework and compress time-to-market.
Global-to-Regional Sourcing Transition
Reduce supply chain risk. We bridge global and domestic sourcing for resilience.
Fulfillment & Lifecycle Management
End-to-end management from first build to end-of-life, including warehousing and Kanban replenishment.
Quality Assurance & Compliance
IPC-certified processes, AOI, X-ray and traceability for medical, defense, and aerospace standards.
.webp)
Rapid Scaling
Prototype today, scale to full production tomorrow.
Quality Management System
Fully documented QMS with traceability, corrective action, and continuous improvement processes embedded at every step.
.webp)
Our Quality Policy
Zero-defect mindset. Every board, every build, every cable assembly is held to the same uncompromising standard.
.webp)
Certifications
ISO 9001, AS 9100D and certified to IPC standard with ESD control, IPC-trained staff, and full compliance documentation for regulated industries.
Markets We Serve
Built for the world's most demanding industries
From the operating room to the flight deck, Sunburst Electronics delivers precision electronics contract manufacturing services where reliability is non-negotiable.
Aerospace
Complex Industrial Controls
Advanced Computing
Medical Technologies
Defense
Next-Gen Communications
Oil and Gas
.webp)
Robotics
Transportation
.webp)
Consumer Electronics
Service and Capabilities
Everything you need under one roof
BGA and micro BGA
Prototype through full production
Conformal coatings, potting
Wave Solder, selective solder, hand solder
DI water and no-clean
Full turnkey assemblies
Labor only, customer consigned components
- PCB assemblies for rugged embedded systems
Enclosure assembly
Chassis assembly
Electro-mechanical assembly
Environmental stress screening
-Burn-in
-Vibration
-Software loadingMechanical revisions/configurations
.webp)
Specialized Builds:
-Explosion Proof Assemblies
-Medical Device Assemblies
-Large Cabinets and Control Panel
Assemblies
-Highly Complex Data ServersRuggedized box builds engineered to MIL-STD-810 and MIL-STD-461 standards, for mission-critical military and aerospace applications
Custom Cable Assemblies and wire harnesses, including power, coaxial, fiber-optic cables and other
Precision wire prep and termination, including automated wire cutting, stripping, crimping of terminals, plug housing assembly, and heat-shrink applications
Built to IPC/WHMA-A-620 standards for cable and wire harness assemblies
Labeling, braiding, overmolding, and EMI shielding
Comprehensive testing capabilities: Hi‑Pot, continuity, insulation resistance, pull/insertion/rotation/extraction, salt‑spray, vibration, bending
Industry-spanning expertise across aerospace (aircraft, satellites), medical, automotive, telecom, industrial, and ag-tech sectors—delivering tailored harness solutions
Lifecycle management
Circuit board schematic and layout engineering
Input of board design optimization
Box-build for turnkey solutions
Hardware, software and firmware engineering
Development of functional test and fixtures
New product introduction
LabView software test systems
%20(1).webp)
Functional testing
Vibration testing
Environmental stress screening
Programming
Customized burn-in cycling
In-circuit testing
Production-test planning
Functional test development
Design for Manufacturibility
Our potting services provide rugged protection for your assemblies in extreme environments:
Moisture, chemical, and dust resistance
Mechanical reinforcement against vibration and shock
Electrical insulation and thermal management
We offer precision conformal coating solutions to extend the durability and reliability of your electronics:
Acrylic, silicone, urethane, and parylene coatings
Spray, dip, brush, and selective coating methods
High-dielectric strength and environmental resistance
Precise masking to protect critical components
IPC-CC-830 compliance
Our testing capabilities ensure that every product meets the highest performance and reliability standards required in electronics contract manufacturing services:
Functional testing of assembled systems
Vibration and burn-in testing for early failure detection
Environmental Stress Screening (ESS)
In-circuit testing with flying probe systems*
LabVIEW-driven automated test systems
Programming and production-level test planning
We specialize in high-precision BGA and micro-BGA assembly, ensuring reliable performance for complex, densely packed PCBs used in mission-critical systems. Our capabilities include:
Automated BGA and micro-BGA placement and reflow using high-accuracy equipment
X-ray inspection and rework systems to verify hidden solder joints and ensure long-term reliability
Precision rework stations equipped with split-vision alignment and controlled reflow profiles
Defect detection is a key part of electronics contract manufacturing services.
Our X-ray inspection capabilities provide detailed, non-destructive insight into the internal structure of complex PCB assemblies, ensuring quality and reliability where traditional visual inspection cannot reach.
Highlights:
-High-resolution imaging to visualize hidden solder joints, vias, and internal layers
-Defect detection for BGA, micro-BGA, and CSP packages, including voids, bridging, cracks, and misalignment
-Real-time image capture and analysis for fast root cause identification of soldering defects
-Advanced analysis software for precise void measurement, documentation, and trend reporting
-Essential for HDI, multilayer, and densely populated boards where conventional inspection falls short
-Trusted in aerospace, medical, and defense electronics where solder joint integrity is critical
Support
Frequently asked questions
Quick answers to the questions we hear most often from engineers, procurement teams, and program managers evaluating a new electronics contract manufacturer.
What does Sunburst Electronics manufacture?
Sunburst Electronics is a US-based electronics contract manufacturer providing printed circuit board assembly (PCBA), electro-mechanical box builds, and custom cable and wire harness assemblies. We serve defense, aerospace, medical, industrial, advanced computing, and other regulated and high-reliability markets from a single facility in Erie, Pennsylvania.
Where is Sunburst Electronics located?
Sunburst Electronics is headquartered and manufactures at 420 East Bayfront Parkway, Erie, Pennsylvania 16507. All builds are produced onshore in the United States.
When was Sunburst Electronics founded?
Sunburst Electronics was founded in 1976 and has operated continuously as an electronics manufacturing services provider for nearly five decades.
Is Sunburst Electronics ITAR registered and AS9100D certified?
Yes. Sunburst Electronics is ITAR registered with the US Department of State and holds active AS9100D and ISO 9001:2015 certifications. We routinely support controlled-data programs for defense and aerospace customers.
What production volumes can Sunburst Electronics handle?
Sunburst Electronics supports the full volume spectrum, from prototype and low-volume high-mix programs through production runs in the thousands per year. A dedicated prototype SMT line enables fast new product introduction (NPI) without disrupting production schedules.
What industries does Sunburst Electronics serve?
Defense, aerospace, medical technologies, industrial controls, advanced computing, next-generation communications, oil and gas, robotics, transportation, IOT and consumer electronics. These are regulated and high-reliability markets where build quality, compliance, and traceability are critical.
What is the difference between an EMS provider and a contract manufacturer?
The terms are used interchangeably in the electronics industry. EMS stands for Electronics Manufacturing Services. Both refer to companies that build electronic products on behalf of OEM customers, typically covering PCB assembly, box build, cable assembly, testing, and supply chain management. Sunburst Electronics is an EMS provider and a contract manufacturer — the same thing.
What assembly technologies does Sunburst Electronics use?
Sunburst Electronics performs high-speed surface mount (SMT), through-hole (PTH), BGA and micro-BGA placement, and hybrid assemblies. Substrates supported include rigid, flex, FR-4, metal, and hybrid boards. We offer RoHS-compliant and tin-lead options, with full automated optical inspection (AOI) and X-ray inspection.
Does Sunburst Electronics offer engineering services?
Yes. Sunburst Electronics provides design-for-manufacturability (DFM) and design-for-test (DFT) reviews, test fixture development, process engineering, schematic and layout support, firmware loading, and full new product introduction (NPI) program management.
Does Sunburst Electronics handle cable and wire harness assembly?
Yes. Sunburst Electronics builds custom cable assemblies and wire harnesses including power, coaxial, and fiber-optic cables. Assemblies are produced to IPC/WHMA-A-620 standards with automated wire prep, crimping, EMI shielding, and full electrical testing including hi-pot, continuity, and insulation resistance.
Does Sunburst Electronics handle turnkey and consigned assembly?
Yes. Sunburst Electronics offers both full turnkey assembly, where we procure all components on your behalf, and consigned (labor-only) assembly, where you supply the components and we provide the build. Many customers operate a hybrid model where critical or customer-specific parts are consigned and the rest is turnkey.
What testing capabilities does Sunburst Electronics offer?
Sunburst Electronics provides functional testing, in-circuit testing, flying probe testing, automated optical inspection (AOI), X-ray inspection, environmental stress screening (ESS), vibration testing, burn-in cycling, and LabVIEW-driven automated test systems. Test fixture development and production test planning are offered as part of engineering services.
Does Sunburst Electronics offer conformal coating and potting?
Yes. Sunburst Electronics provides conformal coating using acrylic, silicone, urethane, and parylene materials, applied via spray, dip, brush, or selective coating methods to IPC-CC-830 compliance. Potting services protect assemblies against moisture, chemical exposure, dust, vibration, and shock, with thermal management compounds available for heat-sensitive applications.
Can Sunburst Electronics build ruggedized electronics for military applications?
Yes. Sunburst Electronics builds ruggedized electronics engineered to MIL-STD-810 (environmental conditions) and MIL-STD-461 (electromagnetic compatibility) standards. Combined with our ITAR registration and AS9100D certification, this allows us to support mission-critical defense and aerospace programs that require controlled-data handling and high-reliability assembly.
Does Sunburst Electronics handle BGA and micro-BGA assembly?
Yes. Sunburst Electronics performs high-precision BGA and micro-BGA placement and reflow using automated equipment with split-vision alignment and controlled reflow profiles. X-ray inspection verifies hidden solder joints, and dedicated rework stations support repair of complex, densely populated boards.
What quality standards does Sunburst Electronics build to?
Sunburst Electronics maintains a fully documented quality management system certified to AS9100D (aerospace) and ISO 9001:2015. Operators are IPC-trained and certified to J-STD-001 (soldered electrical assemblies) and IPC-A-610 (acceptability of electronic assemblies). Cable assemblies are built to IPC/WHMA-A-620 standards.
Does Sunburst Electronics provide supply chain management services?
Yes. Sunburst Electronics offers full supply chain management including component sourcing, inventory management, kitting, Kanban replenishment programs, last-time-buy planning, and obsolescence monitoring. We maintain an integrated MRP system that provides end-to-end traceability from receipt of components through shipment of finished assemblies.
What is the typical lead time for PCB assembly at Sunburst Electronics?
Lead times depend on component availability, build complexity, and order volume. Standard PCB assembly programs typically ship in four to six weeks from receipt of all materials. Prototype builds on the dedicated NPI line can ship faster. Long-lead components — particularly semiconductors during constrained markets — are the most common driver of schedule risk, which is why we engage on sourcing early.
Does Sunburst Electronics handle medical device manufacturing?
Yes. Sunburst Electronics manufactures electronics for medical device applications including diagnostic equipment, patient monitoring systems, and therapeutic devices. Our AS9100D-aligned quality management system, traceability infrastructure, and IPC-trained workforce support the documentation and process discipline required for medical electronics, though customers requiring full ISO 13485 certification should confirm scope with us directly.
Is Sunburst Electronics a small business?
Yes. Sunburst Electronics is a small business by federal government size standards, which can be relevant for customers operating under federal procurement programs, small business set-asides, or supplier diversity initiatives. CAGE code and other compliance documentation are available on request.
What information should I include when requesting a quote?
To receive an accurate quote from Sunburst Electronics, include the bill of materials (BOM) with manufacturer part numbers, Gerber files or fabrication drawings, assembly drawings, expected annual volumes, target lead times, applicable compliance requirements (ITAR, RoHS, MIL-STD), and any special process requirements such as conformal coating or specific test coverage. The more complete the package, the faster and more accurate the quote.
How do I request a quote from Sunburst Electronics?
You can request a quote by calling +1 (814) 461-9120, emailing sales@sunb.com, or using the contact form on our website. To accelerate the quote, please include your Gerber files, bill of materials (BOM), expected annual volumes, and any special compliance or testing requirements.
Quality Commitment
We deliver quality
Build Your Career With Us
Several of our team members have spent their entire careers at Sunburst. If you are willing to learn and take pride in careful, hands-on work, we would like to hear from you. Electronics manufacturing experience is helpful but not required.
View Careers