As featured in 'Fabs and Labs' in the December 2024 issue of Microwave Journal, Microsembly is proud to be recognized for our state-of-the-art manufacturing capabilities and testing services that support the RF/microwave industry.
Based in Merrimack, New Hampshire, our 20,000-square-foot facility is equipped with ISO 14644-1 compliant Class 7 and Class 8 cleanrooms, positioning us to serve a diverse range of customers with high-performance RF and microwave needs.
Prototyping with a Focus on Design for Manufacturability (DFM)
At Microsembly, we emphasize Design for Manufacturability (DFM) during the prototyping stage, integrating practical manufacturing insights into the design process. Smaller companies benefit from our expertise in refining designs to avoid costly adjustments during production, while larger manufacturers can leverage our DFM insights to validate product iterations before scaling. Our cleanroom environments support contamination-sensitive processes like die-attach, which is critical for high-frequency RF and optical components, helping our clients achieve high reliability in even the most demanding applications.
Advanced Manufacturing Processes
Once a design is validated, our manufacturing capabilities offer a range of specialized techniques suited to high-performance RF/microwave applications. These include eutectic and epoxy die attach, wire and ribbon bonding, and the direct attachment of beam lead diodes for minimized parasitics in high-frequency circuits.
Additional manufacturing capabilities include:
- Custom Coil Fabrication and Feedthrough Soldering — Essential for clients requiring specific RF and magnetic properties, allowing tailored solutions for unique design needs.
- Encapsulation and Wafer Processing — Adding protection and durability to components, readying them for rigorous environments.
With these advanced processes, Microsembly supports complex builds and component integrations, adding significant manufacturing capacity without the need for clients to expand in-house facilities.
High-Frequency Testing and Quality Control up to 110 GHz
Our testing capabilities reach up to 110 GHz, enabling precise validation of RF/microwave and millimeter-wave chips, components, and assemblies across the full range of critical electrical and mechanical performance metrics. For smaller design suppliers, these capabilities eliminate the need for costly in-house high-frequency testing equipment, while larger manufacturers benefit from an immediate capability to augment their quality control (QC) and inspection needs.
Our comprehensive testing suite covers:
- RF and EMI/EMC performance
- Mechanical stress testing
- Environmental condition simulation
These capabilities ensure reliability from basic active and passive components to complex, fully integrated microwave assemblies (IMAs) like upconverters and transceivers.
Quality control is built into each phase of production, with rigorous in-process inspections and certifications including ISO-9001, ITAR Registration, ANSI/ESD S20.20, and IPC-A-610, along with J-STD-001 (Space Addendum). These practices reinforce our commitment to precision, ensuring that products meet the most stringent requirements before reaching the field.
Through our prototyping, manufacturing, and testing services, Microsembly provides a flexible, cost-effective, on-demand partner relationship. Stocking plans are also available to respond to just-in-time delivery requirements.
Microsembly serves both smaller RF/microwave suppliers looking for full contract roles and larger manufacturers seeking to fill specific design, production, and testing gaps. We handle complete manufacturing and supply chain demands with unique expertise and service capabilities.
To learn more about our capabilities and how we can support your RF/microwave manufacturing needs, contact us at 603.718.8445 or visit our Request Quote page.