Electro-Mechanical Assemblies
- Cockpit and mission-system assemblies
- Integrated control panels
- Line Replaceable Units
- Ground support equipment
- Operator interface assemblies
Electrical, electronic, mechanical, display, and interconnect systems integrated into fully assembled and tested units.
Polytronix is an electromechanical assembly manufacturer in Richardson, Texas, building LRUs, cockpit assemblies, and panel assemblies in which electrical, electronic, mechanical, and display systems are combined and tested as one unit for aerospace, defense, industrial, and medical programs.
Overview
Polytronix provides complete electro-mechanical assembly services integrating electrical, electronic, mechanical, and display systems into fully assembled and tested units. Our engineering and manufacturing teams support build-to-print and custom-engineered programs from prototypes through large production runs, with manufacturing cells configured for both high-mix and repeat production environments.
We integrate harnesses, PCB assemblies, illuminated panels, displays, chassis, machined components, connectors, switches, relays, thermal-management hardware, and electromechanical devices into fully functional assemblies built to customer, aerospace, defense, industrial, and medical requirements. Assemblies are manufactured and tested in accordance with IPC J-STD-001, IPC-A-610, IPC/WHMA-A-620, QPL-7788, MIL-DTL-7788, DO-160, MIL-STD-810, and customer-specific specifications depending on platform and application requirements.
Our electro-mechanical assembly capabilities support Line Replaceable Units (LRUs), cockpit and mission-system assemblies, control panels, avionics subassemblies, operator interfaces, ground-support equipment, test systems, and integrated box-build programs. We provide complete integration of electrical interconnects, PCB assemblies, backlit panels, enclosure systems, and mechanical hardware under one manufacturing workflow to improve configuration control, traceability, testing consistency, and production efficiency.
Polytronix supports environmental sealing, shock and vibration resistance, thermal management, NVIS-compatible lighting integration, and ruggedized packaging for mission-critical applications operating in harsh aerospace, defense, industrial, and field environments. Assemblies are supported by in-house wiring analyzers, continuity testing, hi-pot testing, functional testing, and configuration-controlled inspection processes.
At a Glance
| Certifications | AS9100D, ISO 9001, ISO 13485, ISO 14001, IATF 16949, ITAR |
|---|---|
| Program Fit | Aerospace, Defense, Industrial, Medical |
| Core Strengths | Integration, Testing, Ruggedization |
| Typical Deliverables | LRUs, Control Panels, Integrated Assemblies |
| Order Quantities | Prototypes to Production Runs |
Electro-Mechanical Assembly Scope
Assemblies & LRUs
- Line Replaceable Units (LRUs)
- Cockpit and mission-system assemblies
- Avionics subassemblies
- Box-build integration
- Rack-mounted and chassis assemblies
Panels & Operator Interfaces
- Integrated control panels and illuminated assemblies
- Operator interface assemblies
- Display and monitor integration
- Electrical control assemblies
Integration & Support Equipment
- PCB and enclosure integration
- Ground support equipment (GSE) assemblies
- Test and maintenance equipment
Build-to-Print & Custom
- Build-to-print integrated assemblies
- Custom electro-mechanical systems
Relevant Applications
Military aircraft
Integrated electro-mechanical assemblies supporting fighter aircraft, rotorcraft, trainers, mission systems, and cockpit platforms including control interfaces, avionics assemblies, illuminated panels, and subsystem integration hardware.
Explore Military ProgramsCommercial aerospace
Cockpit interfaces, display systems, avionics subassemblies, and integrated control hardware supporting commercial aircraft and aerospace ground systems.
Explore Commercial AviationMission and communication systems
Integrated assemblies supporting communication equipment, mission consoles, operator interfaces, RF systems, and tactical electronics platforms requiring ruggedized packaging and environmental qualification.
Explore Military ProgramsGround support equipment
Electro-mechanical systems used in flight-line support equipment, automated test systems, maintenance stations, and deployable support platforms requiring high-cycle durability and serviceability.
Explore Ground SystemsSimulators and training systems
Integrated assemblies developed for full-flight simulators, training devices, and non-flightworthy systems requiring operationally representative controls, lighting, displays, and interface functionality.
Explore Simulation & TrainingIndustrial control systems
Integrated control assemblies, operator-interface systems, enclosure assemblies, and electrical integration programs supporting industrial automation, energy, utilities, and process-control applications.
Explore Industrial EquipmentMedical and life sciences
Electro-mechanical assemblies supporting diagnostic, monitoring, laboratory, and therapeutic equipment manufactured under ISO 13485 quality systems with full process traceability and controlled assembly environments.
Explore Medical & Life SciencesCustom engineered platforms
Customer-specific electro-mechanical assemblies developed for unique operational requirements, environmental conditions, or integration constraints requiring coordinated electrical, mechanical, and manufacturing engineering support.
Explore EngineeringRelevant Capabilities
Box-build integration
Complete integration of PCB assemblies, wire harnesses, connectors, displays, mechanical hardware, and enclosure systems into fully assembled units ready for installation or system-level integration. Supports engineering builds with low minimum order quantities through large production runs with full configuration control and traceability.
Explore Box BuildsControl panel assembly
Assembly and integration of illuminated control panels, switch panels, annunciators, and operator-interface systems for aerospace, defense, industrial, and simulator applications. Assemblies incorporate switches, potentiometers, indicators, displays, connectors, and integrated wiring harnesses built to customer and MIL-spec requirements.
Explore Instrument PanelsLRU and avionics assembly
Manufacture and integration of Line Replaceable Units (LRUs) and avionics assemblies supporting cockpit displays, mission systems, communication systems, and subsystem interfaces. Assemblies may incorporate microcontrollers, FPGA-controlled electronics, display systems, environmental sealing, and ruggedized chassis integration.
Explore Box BuildsPCB and electronics integration
Integration of surface-mount, through-hole, and mixed-technology PCB assemblies into electro-mechanical platforms. Includes board mounting, cable routing, grounding, shielding, connector integration, and mechanical fastening for complete system-level assemblies.
Explore PCB AssemblyHarness and cable integration
Integration of internal wire harnesses, RF cables, power distribution wiring, and signal-routing assemblies into electro-mechanical units. Harnesses are manufactured and inspected to IPC/WHMA-A-620 Class 2 and Class 3 workmanship standards with continuity and functional verification.
Explore HarnessesDisplay and HMI integration
Integration of LCD displays, annunciators, touchscreen interfaces, NVIS-compatible lighting systems, indicators, and operator-control interfaces into integrated assemblies. Supports military and commercial aerospace applications requiring ruggedized human-machine interface systems.
Explore DisplaysMechanical chassis and enclosure assembly
Assembly of chassis structures, mounting trays, panels, brackets, card guides, heat sinks, and enclosure systems supporting electronic and electro-mechanical platforms. Includes installation of shock mounts, fasteners, shielding, thermal interfaces, and environmental sealing components.
Explore Box BuildsEnvironmental sealing and ruggedization
Assemblies can be configured for harsh-environment operation including vibration resistance, environmental sealing, thermal management, EMI shielding, UV stability, and extended-temperature performance. Manufacturing processes support compliance with MIL-STD-810 and customer environmental qualification requirements.
Explore RuggedizationFunctional and DITMCO testing
Functional verification of assembled units using continuity analyzers, DITMCO testing systems, hi-pot testing, switching verification, and application-specific functional testing. Supports validation of illuminated panels, switch assemblies, harnesses, integrated electronics, and complete electro-mechanical systems.
Standards and Compliance
IPC workmanship standards
- IPC J-STD-001 - Soldered Electrical and Electronic AssembliesConformance
- IPC-A-610 - Acceptability of Electronic AssembliesConformance
- IPC/WHMA-A-620 - Acceptability of Cable, Wire, and Harness Assemblies (Class 2/3)Conformance
Referenced standards and environmental qualifications
- MIL-DTL-7788 and QPL-7788 - Illuminated PanelsRegistered
- MIL-STD-810 - Environmental Engineering Considerations and Laboratory TestingConformance
- DO-160 - Environmental Conditions and Test Procedures for Airborne EquipmentConformance
Third-party recordConformance claimed
MIL-DTL-7788 and QPL-7788 — U.S. Defense Logistics Agency (qualifying activity for the QPL-7788 listing). Certificates of record →
Frequently Asked Questions
- Who makes integrated electro-mechanical assemblies and LRUs?
- Polytronix makes integrated electro-mechanical assemblies in Richardson, Texas, including Line Replaceable Units (LRUs), cockpit and mission-system assemblies, avionics subassemblies, and control panels. We integrate harnesses, PCB assemblies, illuminated panels, displays, chassis, machined components, connectors, switches, and relays into fully assembled and tested units for aerospace, defense, industrial, and medical programs.
- What standards does Polytronix build electro-mechanical assemblies to?
- Polytronix manufactures and tests electro-mechanical assemblies in accordance with IPC J-STD-001, IPC-A-610, IPC/WHMA-A-620, QPL-7788, MIL-DTL-7788, DO-160, MIL-STD-810, and customer-specific specifications. Integrated assemblies are supported by in-house wiring analyzers, continuity testing, hi-pot testing, DITMCO testing, and functional testing under configuration-controlled inspection processes.
- Does Polytronix ruggedize electro-mechanical assemblies for harsh environments?
- Yes. Manufacturing processes support compliance with MIL-STD-810 and customer environmental qualification requirements. Polytronix supports environmental sealing, shock and vibration resistance, thermal management, NVIS-compatible lighting integration, and ruggedized packaging for mission-critical applications operating in harsh aerospace, defense, industrial, and field environments.
- Does Polytronix support build-to-print and prototype electro-mechanical programs?
- Yes. Assemblies are built under AS9100D and ISO 9001:2015 registration (Richardson, TX campus; PRI Certification cert 20204) and ITAR registration. Polytronix supports build-to-print and custom-engineered programs from prototypes through large production runs, with manufacturing cells configured for both high-mix and repeat production environments.
- What makes an assembly a line replaceable unit (LRU)?
- A line replaceable unit is built to be exchanged in the field without component-level repair, so the enclosure, connectors, mounting and configuration control matter as much as the electronics inside. Polytronix builds LRUs as sealed, serialized, configuration-controlled units with the connector and mounting defined by the platform, under AS9100D and ITAR registration, so a failed unit is swapped and the platform is returned to service.
Discuss Your Electro-Mechanical Assembly Requirements
Send your assembly drawing and interface list. We confirm build approach, integration, and test before first article.
Quality & Compliance
Polytronix maintains active third-party registrations spanning aerospace, medical, automotive, and environmental quality systems, verified by accredited registrars.
View Certifications- Registered: AS9100DAerospace QMS · Registrar: PRI Certification
- Registered: ISO 9001:2015Richardson, TX · Registrar: PRI Certification
- Registered: ISO 13485:2016Medical devices
- Registered: ISO 14001:2015Environmental
- Registered: IATF 16949:2016Automotive
- Registered: FAA Part 145Repair Station 8PTR524C
- Compliant: EASA Part 145US–EU bilateral recognition
- Registered: ITARDDTC registration