Engineering

Contract Engineering provides essential services to aid product launch and innovation.

Our expertise can be customized to meet your need.

Electronic ControlsRefrigerationHarness
Overview
A Supply Chain that includes Contract Engineering services gets stronger from conception to production. InSource includes contract engineering support in Electronics, Refrigeration, and Wire Harness, which keeps the focus on deadlines, parts availability, and design for manufacturing.
Planning
engineering controls planning
Planning
Requirements Planning You know the market. We know design. You give us the feature set, target cost, and timing. We give you feedback, candor, and results.
Conceptual Brainstorming Tap into our broad experience for custom design approaches and new ideas. We offer a fast introduction to the market with a capable product.
Specification Development Specifications are broadly defined in the beginning and detail is added just in time. This preserves flexibility throughout the design process.
Phased Scheduling The highest value features are created first. You decide when sufficient features exist to make a viable product that can be upgraded later.
Ongoing Communication We will communicate throughout the process to prioritize features, create details, and track schedule performance.
Hardware
engineering_controls_hardware
Hardware
Digital and Analog Design Our electrical engineers have proven experience with a large variety of components and circuits.
Schematic Capture We use PADS to allow collaboration with other designers. We have streamlined procedures to export to manufacturing.
PCB Layout Our designs maximize performance and minimize defects. Our in-house production feedback loop creates continuous improvement.
Wire Harness We design and produce wire harnesses with specialties in laser etched connector marking, braided loom, overmolding, and testing.
Enclosure Design With 3D design tools, we can create custom molded plastic or we can CNC rout standard enclosures.
Focus on Cost You will benefit from our knowledge of volume component costs, process times, and assembly methods.
Software
engineering_controls_software
Software
Agile Development Process Our programming team works together to specify, code, test, and document entire features before moving on to lower priority features. This ensures that you get a functional, tested product, with must-have features quickly.
Embedded C Microcontroller Software We have written code for 8, 16, and 32 bit projects for Atmel, TI, Motorola, and Microchip. We specialize in Microchip design due to cost and availability.
Communication Protocols: CAN, USB, WIFI, etc. Interconnections are extremely important when focusing on modular designs. We have significant experience with protocol design.
Field Updateable Boot-loaders We have written update mechanisms from USB, SD card, serial, CAN, WIFI, SPI, and I2C.
Supporting PC Applications We often create PC applications to interface with the product being designed. They range from simulation software to software update tools to automated test applications.
Validation
Engineering Controls Validation
Validation
Quick Turn Electronic Prototypes Quantity range: 1 to more than 100. Lead time: 1 – 3 weeks – the entire process includes bare board production, surface mount assembly, and through-hole soldering.
Verification and Validation Testing plans are created and executed throughout the design process as features are created. Tests are automated to simulate a wide variety of conditions. Results are documented and used to improve the design before release.
Agency Approvals We interface with test labs when seeking UL, CE, FCC, and other agency approvals.
FMEA and DFM Reviews Our knowledgeable manufacturing engineers and production supervisors review new designs for potential defects and costly labor steps.
Beta / Pilot Production We can move easily from prototypes into production with in-house circuit board and wire harness capabilities.
Manufacturing Test Design We love to share our experience developing automated testers. A good manufacturing test will be independent of operator judgement, exercise all circuits, and report specific defects.
Production
Engineering Controls Production
Production
Surface Mount Assembly Our systems control production bills of materials (BOMs), verify reel setup, and automatically inspect each component (AOI)
Through-Hole and Robotic Soldering Surface mount components are used wherever possible. Most other components are compatible with our robotic soldering equipment. Hand soldering is used for direct wire and cable attachment.
Wire Harness Fabrication We have automatic wire processing lines that measure quality on every crimp. Each harness is tested for continuity, shorts, and inline component polarity.
Final Assembly and Testing Whether assembled into a plastic enclosure or potted into a box, every device is tested at least once. We have a custom defect tracking system to provide feedback for design and process improvements.
Manufacturing Documentation We are the connoisseurs of our own design documentation. Efforts are made to be complete, clear, and concise.
Support
engineering_controls_support
Support
Design and Process Improvements Most surface mount defects can be eliminated through correct copper pad and stencil aperture sizing. Products are routinely reviewed for opportunities to remove defects, assembly time, or component cost.
Solutions for Unavailable Components Every effort is made to create designs with components that will be available throughout the product life cycle. If parts become obsolete or scarce, we are prepared to find alternates or change the design to eliminate the bottleneck.
Warranty We offer warranty and refurbishment programs based on contract negotiations.
Service and Repair For products that are out of warranty, we offer cost effective solutions for service and repair.
Field Failure Analysis Data is collected on root cause of failures returned in or out of warranty. Lessons learned are incorporated in later revisions and new products.
Planning
engineering_refrigeration_planning
Planning
Requirements Planning You know the market. We know design. You give us the feature set, target cost, and timing. We give you feedback, candor, and results.
Conceptual Brainstorming Tap into our broad experience for custom design approaches and new ideas. We offer a fast introduction to the market with a capable product.
Specification Development Specifications are broadly defined in the beginning and detail is added just in time. This preserves flexibility throughout the design process.
Phased Scheduling The highest value features are created first. You decide when sufficient features exist to make a viable product that can be upgraded later.
Ongoing Communication We will communicate throughout the process to prioritize features, create details, and track schedule performance.
Component Selection
Engineering Refrigeration Component Selection
Component Selection
Compressor InSource uses Cubigel compressors and will use our resources to select the proper one for your application.
Coils Our coil manufacturer supports our efforts to make sure that your system works.
Valve, Filter/drier, Receiver We can help determine which components are needed in your design.
Wire Harness or Power Cord We design and produce wire harnesses and power cords.
Sheet Metal Design We can customize your base plate and fan bracket if volumes support it.
Focus on Cost You will benefit from our knowledge of volume component costs, process times, and assembly methods.
Prototype
Engineering Refrigeration Prototype
Prototype
Quick Turn Prototypes Quantity range: 1 to more than 100. Lead time: 1 – 3 weeks – depends on availability of parts
Verification and Validation After the system is built, we can ship it to you for testing or complete testing here in our environmental chamber.
Agency Approvals We interface with test labs when seeking UL, and other agency approvals.
FMEA and DFM Reviews Our knowledgeable manufacturing engineers and production supervisors review new designs for potential defects and costly labor steps.
Beta / Pilot Production We can move easily from prototypes into production with in-house copper tube fabrication, wire harness production and complete evacuation and charging lines
Production
Engineering Refrigeration Production
Production
Copper Tube Fabrication We cut, bend, end form copper tubing from 1/8″ cap tube to 2″ water pipe.
Brazing Our AWS certified employees braze brass, copper, and steel.
Wire Harness Fabrication We have automatic wire processing lines that measure quality on every crimp. Each harness is tested for continuity, shorts, and inline component polarity.
Final Assembly and Testing Each system is tested for leaks and charged. R134a, R410a, R404a, or Nitrogen depending on your specifications.
Manufacturing Documentation We are the connoisseurs of our own design documentation. Efforts are made to be complete, clear, and concise.
Support
engineering_refrigeration_support
Support
Design and Process Improvements We focus on continuous improvement with every build. Products are routinely reviewed for opportunities to remove defects, assembly time, or component cost.
Solutions for Unavailable Components Every effort is made to create designs with components that will be available throughout the product life cycle. If parts become obsolete or scarce, we are prepared to find alternates or change the design to eliminate the bottleneck.
Warranty We offer warranty and refurbishment programs based on contract negotiations.
Service and Repair For products that are out of warranty, we offer cost effective solutions for service and repair.
Field Failure Analysis Data is collected on root cause of failures returned in or out of warranty. Lessons learned are incorporated in later revisions and new products.
Planning
engineering_wireharness_planning
Planning
Requirements Planning You know the market. We know design. You give us the feature set, target cost, and timing. We give you feedback, candor, and results.
Conceptual Brainstorming Tap into our broad experience for custom design approaches and new ideas. We offer a fast introduction to the market with a capable product.
Specification Development Specifications are broadly defined in the beginning and detail is added just in time. This preserves flexibility throughout the design process.
Ongoing Communication We will communicate throughout the process to prioritize features, create details, and track schedule performance.
Component Selection
Engineering Wire Harness Component Selection
Component Selection
Wire We stock a large selection from 28 AWG wire to 4/0 battery cable to multi conductor cable and access to much more.
Terminals We have applicators for AMP/Tyco, Deutsch, Molex, Packard, Panduit and many more.
Looming Nylon braiding or corrugated loom, we got your wire covered.
Over molded ends We design tooling and produce plastic injected over molding that cover many standard connectors.
Potting We can weatherproof your custom cavity with various potting compounds.
Focus on Cost You will benefit from our knowledge of volume component costs, process times, and assembly methods.
Prototype
Engineering Wire harness Prototype
Prototype
Quick Turn Prototypes Quantity range: 1 to more than 100. Lead time: 1 – 3 weeks – depends on availability of parts
Agency Approvals UL certified wire harness manufacturer for ZPFW2 and ZPFW8.
FMEA and DFM Reviews Our knowledgeable manufacturing engineers and production supervisors review new designs for potential defects and costly labor steps.
Beta / Pilot Production We can move easily from prototypes into production.
Production
engineering_wireharness_production
Production
Cut, Mark, Strip We cut, mark, strip and terminate in one operation. With multiple color options, we can mark on any color wire.
Routing InSource has developed a peg board system instead of bed of nails so that we can switch over a line very quickly.
Splicing Ultra sonic splicing eliminates butt connectors and piggytails when multiple wires go into one connector or ground plane. This method is recognized by UL when covered by heat shrink
Laser etching We can laser etch directly to a plastic or metal to eliminate costly and time consuming labels that don’t stay on the connector anyways.
Final Assembly and Testing We have testing equipment that measure quality on every crimp. Each harness is tested for continuity, shorts, and inline component polarity.
Manufacturing Documentation We are the connoisseurs of our own design documentation. Efforts are made to be complete, clear, and concise.
Support
engineering_wireharness_support
Support
Design and Process Improvements We focus on continuous improvement with every build. Products are routinely reviewed for opportunities to remove defects, assembly time, or component cost.
Field Failure Analysis Data is collected on root cause of failures returned in or out of warranty. Lessons learned are incorporated in later revisions and new products.