Products and Services

ECI is the leading manufacturer of wire harnesses, sub-assemblies, radiant glass heaters, power cords, and value-added services. Across our global facilities, we manufacture simplistic to complex assemblies, specializing in low volume, high mix products. Our manufacturing process includes cutting and termination, splicing / sealing and heat shrink, molding, assembly, and testing. Our products are made worldwide and distributed to top-tier customers across a wide variety of industries.

ECI’s products are designed to provide total cost solutions to our customers. With an unyielding commitment to excellence and service, we support our customers from new product implementation all the way through to technical support after shipment. Our expert teams anticipate needs and exceed expectations for all projects, ranging from a wire lead to an 800-circuit assembly.

ECI Manufactures the following products:

Harnesses and Wire Leads

ECI has over 50 years of experience manufacturing wire harnesses and leads. Our wire harnesses are configurations of wire or cables cut to specific lengths and finished on their ends with connectors or plugs used to distribute electricity in finished goods. We manufacture simplistic to complex assemblies, specializing in low volume high mix products. ECI harnesses can be found in the top brands worldwide in a variety of industries including home appliances, transportation equipment, heating, ventilation and air conditioning (HVAC) products, construction and agricultural equipment, and vending and industrial machines.

We also specialize in providing the North American motor vehicle market with harnesses, ignition cables, molded parts, electro-mechanical assemblies, engine block heaters and battery blankets. We provide fully integrated manufacturing capabilities with a wide range of technical services including product design, applied engineering, custom manufacturing and integration of wire and wire-related products.

Power Cords

ECI manufactures custom electric cords and cord sets. Our products vary in length and termination and are made to meet our customers exacting standards and agency approvals. Our power cords can be found in consumer products worldwide.

Electro-Mechanical Assemblies

ECI provides a variety of assembly services for component products used in numerous industries including home appliances, transportation, military, aerospace, medical, and commercial applications. We build complex control boxes, electrical consoles, and other sub-assemblies utilizing our expertise in facilities around the world.

We have deep experience in the vertical integration of displays, harnesses, cases, and circuit board assemblies. Our materials group focuses on a strong custom component supply chain so high mix, variable demand projects can be supported.

Electro-Mechanical Capabilities:
    • Electronic / Cable / Mechanical Design Assistance
    • Final System Electromechanical Assembly / Integration
    • Cabinet assembly and test capability
    • Full Turnkey Sourcing Capabilities
    • Sheet metal Fabrication
    • Injection Molding & Vacuum Forming
    • Machine Shop Capabilities
Control and power panels

ECI manufactures control and power panels to customer specifications. Panels range from small and simple to large and complex, with hundreds of model numbers. Complex panels can be configured with up to 20 options, offering over 100,000 possible assembly combinations in a single line.

Control and Power Panels Capabilities:
    • Panels that are configured with an assigned serial number so they can be packed out in sequence in returnable containers
    • Same day firm order and shipping
    • Assembly lines that are efficiently designed by manufacturing, industrial, and test engineers
    • A team with experience building over 2,500 control panels per day
    • Emergency Backup Diesel Generator 230kw
    • Vertical integration with harness and wire capabilities, molded plug assemblies, and sheet metal forming
    • Manufactured in a UL508A certified facility
CUSTOM MOLDED COMPONENTS

To complement our wire harness assembly capabilities, ECI offers an extensive range of custom molded components related to power and signal distribution systems.

Custom Molded Components:
    • Custom over-molded packages for discreet components such as diodes and resistors
    • Custom connectors, caps, and mounting devices
    • Grommets
    • Strain Relief’s

Our in-house tool and die capabilities and our extensive range of mold presses allow us to respond quickly to our customers’ needs and requirements. Our experienced engineers evaluate, design, and develop customized solutions to meet challenging design requirements.

CUSTOM INSERT MOLDING

ECI develops and manufactures custom molded products to meet OEM requirements for the HVAC Industry. We specialize in compressor plugs for the air conditioning industry, as well as PVC and engineered resins for the US, European, and Asian Markets.

POWER DISTRIBUTION AND ELECTRICAL SYSTEMS

Dillblox Power Distribution Modules are designed to provide flexible, easy to configure electrical distribution panels using standard off the shelf components. Dillblox Modules have a unique interlocking edge and can be joined together using the dovetail wedge. The result is the creation of a strong, rigid panel assembly. Standard modules are available to accept most plug-in devices that are widely used in over-the-road, off-road, construction, and agricultural vehicles. Custom designed modules can be provided at a reasonable cost for special applications.

We provide technical assistance for the selection and application of Dillblox power distribution systems, the design of Dillblox for new or different applications, the design of custom connectors and harness components, and the design and drafting of wire harnesses to be used with our Dillblox panels.

We also supply pre-assembled Dillblox Panels.  Whether you want a panel that is ready to wire and silk-screened, or one that’s loaded and electrically tested, we can get the job done.

Learn More about Dillblox Power Distribution Modules

engineering support services

ECI provides extensive design and engineering support. Our services include System Review, Load Center and Connector Design, Wire Systems Design, CAD Documentation, Load Testing, and Prototyping.

Our extensive experience in harness fabrication, engineering support services, and component design and manufacturing allow us to provide the full range of services and support our customers require.

printed circuit board assembly

ECI operates a full service, build-to-order Printed Circuit Board (PCB) manufacturing facility with Surface Mount Technology (SMT) and Pin-Through-Hole (PTH) assembly capabilities. Our SMT lines consist of fully automated stencil printers, high-speed pick and place equipment, automated optical inspection (AOI), and conventional multi-zone reflow ovens. We also use selective solder for the double-sided assemblies, wave solder machines for the mass PTH soldering, and proven design tooling experience to satisfy all printed circuit assembly requirements.

Our services include design support, material procurement and management, account management, In-Circuit Test (ICT), Lead-free or Leaded solder, Functional Test (FCT), debug repair, and/or warranty service.

PCB Assembly Technology Options:
    • Surface Mount Technology (SMT)
    • Pin-Through-Hole (PTH) Technology
    • Hybrid Mixed Technology
    • Leaded or Lead-Free Solder
    • Water Soluble or No-Clean Flux
    • 0201 Chip to 72mm square Ball-Grid-Array (BGA
Circuit Board Construction Services:
    • Rigid Board
    • Flexible Circuit
    • Combined Construction (Rigid and Flex)
    • Single to Multilayer Boards
    • Single or Double Sided
Soldering Capabilities:
    • Selective Soldering
    • Wave Soldering
    • IPC-JSTD Certified Hand Soldering
    • ROHS Compliant
Inspection Capabilities:
    • Solder Paste Inspection (SPI)
    • Automated Optical Inspection (AOI)
    • 5-axis X-ray Inspection
    • IPC-A-610 Class 1, 2 & 3 Certified Inspectors
Circuit Testing Capabilities:
    • In-Circuit Test (ICT)
    • Functional Test (FCT)
    • Continuity Testing, Debug & Diagnostics
    • Dielectric Withstand Testing (HIPOT)
Tooling Design Include:
    • Stencils
    • Reflow & Wave Pallets
    • Assembly Fixtures
    • PEM Nut Installation Tooling
conformal coating and potting

When there is a need to protect circuit assemblies from harsh environments and strengthen connections, conformal coating and potting are methods used to cover those sensitive electronics and cable harnesses for long-term use in the field. ECI has coating and potting capabilities for circuit and harness assemblies. Silicone, acrylic, and polyurethane based coating and potting materials can be used depending on customer requirements.

We use a wide variety of processes to cover the circuit assembly in only the areas requested by our customers. Conformal coating can be brushed, masked, dipped, and sprayed to any thickness required.

Environmental Circuit Protection Methods:
    • Conformal Coating
    • Potting
    • Encapsulation
Materials Used:
    • Silicone
    • Acrylic
    • Polyurethane
    • 2-part Epoxies
    • Single-Sided
Applications:
    • Hand Brushing
    • Air and Mechanical Assisted Dispensing
    • Metered Spraying
    • Selective Area
    • Pour Filing
diagnostic services: x-ray and circuit assembly debugging

If an ailing electronic assembly requires diagnosis, ECI’s highly trained and skilled technicians and engineers probe through the electrical schematic to identify the cause of failure.

Our test equipment includes oscilloscopes, multimeters, and fine tipped test probes, as well as, a 2000X magnification, pan & tilt 5-axis X-ray to take care of the hard-to-reach root cause of circuit assembly failures.

We work with our customers to validate functional test equipment, debug test setup, repair customer supplied test systems and tooling, and provide test procedure feedback to clarify any process conflicts or missing test steps.

Inspection Capabilities:
    • Solder Paste Inspection (SPI)
    • Automated Optical Inspection (AOI)
    • 5-axis X-ray Inspection
    • IPC-A-610 Class 1, 2 & 3 Certified Inspectors
Circuit Testing Capabilities:
    • In-Circuit Test (ICT)
    • Functional Test (FCT)
    • Continuity Testing, Debug & Diagnostics
    • Dielectric Withstand Testing (HIPOT)
Integrated Marine Panel Assembly

ECI also provides integrated marine panel assembly services. Our marine panel assembly capabilities are designed to meet customers’ specifications and include:

    • Vacuum Forming
    • Vinyl Wrapped Covering
    • Marine/AG/Construction AC Control Panels
COLD WEATHER STARTING AIDS

ECI manufactures cold weather starting aids, engine block heaters, and power cords for automotive application. Our capabilities also include custom power cords molding and electro-mechanical assemblies.