Zillion GBS
03 — CAPABILITIES

FROM PRODUCT IDEA TO MARKET-READY SCALE

Our capabilities cover the complete industrial journey—from scoping and schematic design to mass production and global distribution. Every stage is governed by strict engineering qualification gates.

Stage 01: DEFINE - Architecture, Requirements & Feasibility
STAGE 01

DEFINE — Architecture, Requirements & Feasibility

Gate: PRD & Architecture Sign-Off

Every successful industrial project starts with crisp scoping. We translate business intent into technical Product Requirement Documents (PRDs), perform target cost BOM modeling, and establish regulatory roadmaps before laying down a single trace.

Business Need Target price & margin
Product Brief PRD & specs
Regulatory Scoping BIS, CE, UL, RoHS
Component Lifecycle Obsolescence audit
STAGE 02

DESIGN — Electronics, Embedded, PCB & Mechanical CAD

Gate: Schematics & Gerbers Approved

Our 50+ multidisciplinary engineers execute schematic capture, high-speed PCB layouts (up to 32 layers), micro-via fanouts, firmware architecture, and mechanical enclosure engineering with comprehensive thermal simulation.

Circuit & PCB Design High-speed DDR, RF, SI/PI simulation
Embedded & Firmware RTOS, Bare-Metal, Linux, BLE/Wi-Fi/4G
Mechanical Design 3D CAD, Moldflow, IP67/IP68 sealing
Stage 02: DESIGN - Electronics, Embedded, PCB & Mechanical CAD
Stage 03: PROTOTYPE - Rapid Tooling, DFM & Validation
STAGE 03

PROTOTYPE — Rapid Tooling, DFM & Validation

Gate: EVT / DVT Validation Complete

Fast-turn prototypes (24 to 48 hour turnaround on PCBA) allow physical testing before committing to production tooling. We subject builds to stringent DFM (Design for Manufacturing) and DFA (Design for Assembly) reviews.

Prototype Development Quick-turn PCBA, 3D SLA/SLS prints
DFM & DFA Audits Component spacing, thermal pad relief
Validation & Testing Signal probing, environmental cycling
STAGE 04

SOURCE — Strategic BOM Procurement & AVL Governance

Gate: 100% BOM Secured & Traced

Direct relationships with global semiconductor manufacturers and tier-1 franchised distributors guarantee authentic components, optimum pricing, buffer stock agreements, and domestic value addition (DVA).

Active/Passive ICs Franchised allocation
PCB Substrates FR4, High-Tg, Rogers
Polymers & Resins PA66-GF, PC/ABS, PBT
Metals & Rubber CRCA sheet, AL5052, EPDM
Stage 04: SOURCE - Strategic BOM Procurement & AVL Governance
Stage 05: MANUFACTURE - High-Speed SMT, Tooling & Electromechanical Assembly
STAGE 05

MANUFACTURE — High-Speed SMT, Tooling & Box Build

Gate: PVT First Pass Yield > 99%

Equipped with high-speed Fuji & Yamaha lines in ISO 8 / Class 100,000 cleanrooms, 10-zone Nitrogen reflow ovens, automated Komax wire harness crimpers, 80T–1,700T injection moulding, and robotic CNC sheet metal fabrication.

SMT Assembly 01005 to 0.3mm BGA, PoP
Wire Harness Automated crimping & ultrasonic
Injection Moulding 190 presses (80T–1,700T)
Box Build Turnkey pot, seal & pack
STAGE 06

QUALIFY — 3D AOI, X-Ray, Environmental Stress & Compliance

Gate: Zero-Defect Quality Certificate

Zero-defect policy backed by 100% in-line 3D AOI, 2D/3D X-Ray inspection of BGA solder joints, In-Circuit Testing (ICT), custom bed-of-nails functional test benches (FCT), and environmental burn-in stress screening.

3D AOI & X-Ray Fillet, voiding & alignment
ICT & Flying Probe Open/short component test
Burn-In Testing -40°C to +125°C stress
IP Ingress & Drop IP67/IP68 water & dust
Stage 06: QUALIFY - 3D AOI, X-Ray, Environmental Stress & Compliance
Stage 07: SCALE - Serialization, Warehousing & Global Export
STAGE 07

SCALE — Serialization, Warehousing, Localization & Global Export

Outcome: Market-Ready Scale

When you scale, our supply chain and logistics engine ensures flawless delivery. Every box and board is serialized with laser QR codes, maintained in climate-controlled ESD warehousing, and shipped via Kanban JIT line feeding.

ESD Packaging Custom trays & bags
QR Serialization Lot-level cloud traceability
Kanban & Buffer JIT delivery to OEM lines
Global Export Air & sea freight customs
TECHNICAL SPECIFICATIONS

Capabilities Matrix & Engineering Limits

Category Engineering Limit / Capability Equipment / Technology
PCB Fabrication 1 to 32 Layers, Rigid, Flex, Rigid-Flex; Min Trace/Space 2.5 mil / 2.5 mil; Blind & Buried Vias, Microvias Laser Direct Imaging (LDI), Vertical Continuous Plating, Automated Optical Inspection
SMT Placement Component sizes from 01005 passives up to 100mm² ICs; BGA/Micro-BGA pitch down to 0.3mm; PoP (Package-on-Package) Fuji & Yamaha High-Speed Pick & Place, 10-Zone Nitrogen Reflow, Koh Young 3D SPI
Inspection & Test 100% 3D AOI inspection; 2D/3D X-Ray (void ratio < 10%); In-Circuit Testing (ICT); Flying Probe; Boundary Scan (JTAG) TRI 3D AOI, Nordson Dage X-Ray, Keysight ICT, Takaya Flying Probe, Thermal Chambers
Wire Harness 10 AWG to 32 AWG; High-Voltage EV orange cables; Multi-core shielded harnesses; Ultrasonic wire splicing Komax Alpha 355/550, Schleuniger Strip Series, Cirris Computerized Continuity Testers
Plastic Moulding Tonnage 80T to 1,700T; Part weight from 2g to 12kg; Precision hot-runner tooling; Optical and engineering grades Engel, Toshiba, Haitian servo-hydraulic moulding machines, Sepro robotic parts extractors
Sheet Metal Thickness 0.5mm to 16mm (CRCA, Stainless, Aluminum); ±0.05mm cutting tolerance; Robotic MIG/TIG/Spot welding 4kW/6kW Fiber Laser Cutters, CNC Synchronized Press Brakes, 7-Tank Pretreatment Powder Line
THE OUTCOME

MARKET-READY SCALE

This seven-stage journey is the core operating proposition connecting your product intent to dependable volume production.

Start Your Stage 01 Journey