What is Electro-Mechanical Assembly?
At DureX Inc., we specialize in electro-mechanical assembly—the integration of electrical and mechanical components into a single, functional unit. These assemblies are the heart of countless modern products, powering everything from control panels and diagnostic equipment to smart electronics and industrial automation systems.
Located in Union, New Jersey, our 120,000-square-foot facility is equipped with the tools, technology, and technical talent to take your assembly from concept to completion. Whether you’re a local startup looking to prototype a sensor assembly or an established OEM seeking reliable high-volume cable assemblies, DureX delivers precision-built solutions that meet exacting standards.
With decades of electro-mechanical assembly experience, we help our partners across industries streamline production, enhance product performance, and bring complex devices to life with confidence, right here in the U.S., without the delays and risks of overseas sourcing.
What We Assemble: Electro-Mechanical Assembly
At DureX, we assemble a wide variety of electromechanical systems designed to perform precise functions under demanding conditions, including extreme conditions such as high vibration, heat, and continuous use.
Each assembly is carefully constructed by experienced technicians, using industry-standard practices and strict quality control measures. The integration of electrical and mechanical components results in final products that meet rigorous performance and reliability standards.
Introduction to Electromechanical Assembly
Electromechanical assembly is the process of integrating electrical and mechanical components into a unified system designed to perform a specific function.
This integration involves carefully combining components such as circuit boards, switches, sensors, and mechanical parts to create assemblies that can efficiently transfer electrical energy into mechanical motion—or vice versa—depending on the application.
Electromechanical assemblies are essential in a wide range of industries, from industrial equipment and medical devices to advanced electronic devices, where precise control and reliable performance are critical.
By bringing together electrical components and mechanical components, manufacturers can develop systems that not only perform complex tasks but also meet stringent industry requirements for safety, durability, and efficiency. Sub assemblies often play a key role in this process, allowing for modular design and easier maintenance.
Whether the goal is to automate a manufacturing process, power a medical device, or enable a specific function in an electronic product, electromechanical assembly ensures that all components work together seamlessly to deliver optimal results.
Typical Components in Our Assemblies:
A typical electromechanical assembly includes the following components, many of which are essential components for system reliability:
Circuit Boards – the brains of most electromechanical systems, enabling control, communication, and power regulation. These are essential components for reliable operation.
DIN Rail – a mounting framework used to organize and securely hold various electrical and mechanical parts within assemblies, ensuring efficient layout and maintenance.
Switch Assemblies – toggle, push-button, or custom-designed switches used to control the flow of electrical current. Switch assemblies are essential components in modulating electrical current flow within control systems.
Cable & Harness Assemblies – Routed wiring systems built for durability and performance, critical for safe signal and power transmission.
Sensor Assemblies – detect external stimuli like pressure, temperature, motion, light, heat, or sound, and convert them into actionable electrical signals. Sensor assemblies are essential components in many control systems.
Speed Sensors – used in automotive and industrial assemblies to monitor rotational speed, contributing to system versatility and durability.
Temperature Sensors – important for monitoring and controlling system temperature, ensuring safe and efficient operation in demanding environments.
Power Supplies & Converters – transform incoming electrical energy into the correct voltage and format required for device operation. These are essential components for reliable power delivery.
Box Builds – full-system assemblies housed in metal enclosures, ready for installation.
Cooling Tubes and Heat Dissipation Components – to manage thermal output and ensure optimal performance.
From high-amperage circuits to compact switch panels, DureX has the technical ability and infrastructure to build assemblies for even the most demanding industries. We handle projects ranging from simple toggle devices to complex multi-circuit control systems.
And because we’re based in Union, NJ, local manufacturers benefit from fast lead times, in-person engineering support, and tight production control that overseas vendors simply can’t match.
Our Electro-Mechanical Assembly Capabilities
At DureX, precision isn’t just a goal—it’s a standard. Our electro-mechanical assembly process is built around accuracy, repeatability, and performance. Whether assembling a simple wire harness or a fully enclosed sensor-driven control system, we follow a detailed methodology to ensure every component performs exactly as intended.
Our projects range from compact assemblies for many devices in aerospace, where reliability and precision are critical, to rugged solutions for heavy equipment that demand robust and durable assemblies in harsh industrial environments.
Our Capabilities Include:
Manual & Automated Assembly Operations – Combining the efficiency of automation with the finesse of skilled technicians.
Component Placement & Positioning – Ensuring all electrical and mechanical components are installed according to exact specifications and mechanical drawings.
Circuit Testing & Signal Routing – Verifying electrical signals and continuity to ensure safe, reliable system performance.
Regulation of DC Output Waves – Fine-tuning power supplies and output formatting for sensitive electronic components.
Assembly of Complex Subsystems – From panel assemblies to embedded switch assemblies and multi-part mechanical structures.
We work with both standard components (like circuit breakers, connection heads, and transformers) and specialized, customer-supplied parts. Whether your product requires rugged electromechanical equipment for industrial use or high-precision assemblies for medical devices, DureX provides the flexibility and expertise to support it.
And because all operations are done in-house at our Union, NJ facility, customers enjoy full transparency, local engineering access, and faster delivery, without compromising on quality.
Our Mechanical Assembly Process
At DureX, our mechanical assembly process is built on a foundation of precision, collaboration, and attention to detail. Every project begins with comprehensive design support, where our engineers review detailed blueprints and engineering drawings to map out the assembly operations. This ensures that every component—whether electrical, mechanical, or part of a sub-assembly—is selected and positioned according to exact specifications.
Our experienced team uses a combination of hand tools and specialized equipment to assemble each system, following step-by-step procedures that guarantee consistency and quality.
We carefully select mechanical components and electrical components that are best suited for the intended application, ensuring that the final product functions properly and meets all customer requirements.
Throughout the process, we maintain strict adherence to engineering drawings and quality standards, resulting in electromechanical assemblies that are both reliable and high-performing.
By leveraging our expertise in mechanical assembly and our commitment to excellence, we deliver assemblies that not only meet but exceed our customers’ expectations—every time.
Design & Engineering Support
At DureX, every successful electro-mechanical assembly begins with thoughtful planning and smart engineering. Our in-house team collaborates directly with your engineers to translate concepts into manufacturable solutions, ensuring accuracy, efficiency, and long-term reliability.
Effective panel design is also critical for the proper distribution of electrical power to other connected circuits, supporting system reliability and performance.
Our Engineering Services Include:
Mechanical & Electrical Design Review – We work from detailed mechanical drawings, schematics, and BOMs to validate component compatibility and assembly logic.
Component Sourcing & Optimization – Assistance with sourcing high-performance electrical components and mechanical parts that balance cost, durability, and function.
Custom Assembly Strategies – Tailored solutions that meet unique functional goals such as transferring electrical energy, isolating primary and secondary windings, or meeting compact footprint requirements.
Design for Manufacturability (DFM) – We recommend improvements to streamline your manufacturing process, reduce cost per unit, and improve end-product reliability.
Our engineering support isn’t limited to just the design phase. We stay involved through prototyping, production, and refinement, ensuring your assemblies function properly and meet every performance benchmark.
This level of close collaboration—combined with local accessibility at our Union, NJ facility—gives your team a critical advantage: better communication, faster iterations, and a shorter path to market.
Industries Served
From mission-critical aerospace systems to everyday consumer electronics, DureX Inc. delivers electro-mechanical assemblies that power innovation across industries. Our ability to handle complex, multi-component builds makes us a trusted partner for manufacturers seeking reliability, scalability, and engineering precision.
Applications Across Key Sectors:
Aerospace & Defense
Ruggedized sensor assemblies, switch panels, and cable harnesses built to withstand extreme environments and high-vibration conditions.Automotive & Electric Vehicles
High-durability power supplies, high amperage circuits, and electromechanical components integrated into advanced driver systems and EV platforms.Medical Devices
Precision-built assemblies used in pumps, diagnostic systems, and life-saving equipment. Clean, accurate, and ISO-compliant builds from circuit boards to sensor wires.Industrial Equipment & Automation
Custom panel assemblies, power boxes, and connection heads that control and monitor complex machinery.Consumer Electronics
Compact electro mechanical systems found in devices like electric typewriters, smart home products, and wearables—built for both performance and scale.
Whether you need to detect external stimuli, regulate electrical energy, or manage connected circuits, DureX has the experience and infrastructure to meet your needs. And because we’re based in Union, NJ, we can provide quick turnarounds and face-to-face collaboration throughout the process.
Quality Assurance and Testing
When it comes to electro-mechanical assemblies, precision isn’t optional—it’s critical. That’s why DureX maintains a rigorous, ISO-compliant quality control system that ensures every assembly performs safely, reliably, and as intended.
From the moment your components arrive at our Union, NJ facility, they’re handled with the highest level of care. Our dedicated QA team works alongside our assembly technicians to inspect, test, and validate each build at multiple stages of the production process.
Our Testing and QA Capabilities Include:
Functional Testing of Electrical Circuits
Ensuring all electrical signals pass correctly and that power flows at the correct voltage to every part of the system.Mechanical Fit and Positioning Checks
Verifying that all mechanical components are positioned correctly and align precisely with mechanical drawings.High-Load and Stress Testing
For assemblies used in high amperage circuits or heavy-duty industrial environments, we simulate operating conditions to validate performance and durability.Specialized Instrumentation
We use oscilloscopes, multimeters, and continuity testers to validate everything from DC output waves to sensor response accuracy.Documentation and Traceability
Every build includes detailed test records, part traceability, and inspection reports to meet your regulatory and documentation requirements.
Our team’s commitment to maximum efficiency and flawless function has earned DureX a reputation for delivering products that work right—right from the start.
Achieving Maximum Efficiency in Assembly
Achieving maximum efficiency in assembly requires a deep understanding of how electrical and mechanical components interact within a system.
At DureX, we focus on optimizing every stage of the electromechanical assembly process, from the integration of switch assemblies, sensor assemblies, and cable assemblies to the precise construction of electrical circuits and mechanical subassemblies.
Our team’s extensive electro-mechanical assembly experience allows us to streamline assembly operations, ensuring that each component is installed and connected for peak performance.
We utilize proven techniques such as box builds and harness assemblies to simplify complex wiring and reduce assembly time, all while maintaining the highest standards of quality and reliability.
By carefully coordinating the placement and connection of all components, we create systems that deliver consistent results and meet the rigorous demands of various industries. Our approach to mechanical assembly and electro mechanical integration not only enhances efficiency but also helps control costs and accelerate time to market.
With DureX, you can trust that your assemblies will be built for maximum efficiency—delivering the performance, durability, and value your business needs to succeed.
Why Choose DureX for Electro-Mechanical Assembly
With over 75 years of experience and a fully integrated 120,000-square-foot facility in Union, New Jersey, DureX is more than a contract manufacturer—we’re your strategic partner in precision assembly.
Whether you’re scaling up a new product or improving an existing one, our team offers the expertise, technology, and flexibility to bring your electro-mechanical assemblies to life with unmatched quality and speed.
What Sets DureX Apart:
Deep Electro-Mechanical Assembly Experience
Our seasoned technicians and engineers understand how to balance the interaction of electrical and mechanical components for optimal system performance.Advanced In-House Capabilities
From wire harnesses and box builds to full-panel systems and custom enclosures, all processes—design, fabrication, assembly, and testing—are performed under one roof for seamless coordination.Flexible Volume Production
Whether you need a low-volume prototype or a high-volume production run, we can scale with your needs without compromising quality.Local Access with Global Reach
Being based in Union, NJ allows us to work directly with OEMs across the Northeast—offering fast response times, site visits, and local support while delivering quality that meets international standards.Custom Solutions for Complex Requirements
We specialize in non-standard assemblies, incorporating sensor wires, cooling tubes, and integrated controls to meet even the most challenging technical demands.
At DureX, we don’t just assemble parts—we help you build better products, faster. Our hands-on approach, engineering collaboration, and relentless focus on quality make us the ideal partner for your next electromechanical equipment project.
Frequently Asked Questions
What is an electro-mechanical assembly?
Electro-mechanical assembly is the process of integrating electrical components (like circuit boards, wires, and sensors) with mechanical components (such as housings, switches, and gear systems) to create a fully functional system. These assemblies are critical in everything from medical devices to industrial machinery.
What types of components do you work with?
We assemble a wide range of components, including circuit boards, switch assemblies, sensor wires, power supplies, cable harnesses, panel assemblies, and more. We can also source and integrate standard components like circuit breakers, transformers, and connection heads.
What industries use electro-mechanical assemblies?
We serve clients in the aerospace, automotive, medical, industrial, and consumer electronics industries. Our assemblies are used in applications like switch panels, box builds, sensor-driven controls, and electromechanical equipment for both harsh and regulated environments.
How do you ensure quality and reliability?
Our QA process includes multi-stage inspections, functional and stress testing, and detailed documentation. We test for electrical signal accuracy, correct voltage, and proper mechanical component positioning to ensure that every unit functions flawlessly.
Can DureX support low-volume production or prototyping?
Yes. Our facility is equipped to handle everything from single prototype builds to full-scale production runs. We often support clients during early-stage development, offering design-for-manufacturing guidance and fast-turn prototyping in Union, NJ.
Get Started with DureX Electro-Mechanical Assembly
Ready to streamline your production with high-quality, locally assembled electro-mechanical systems? At DureX, we’re here to support your goals—whether you’re launching a new product, scaling up, or improving system reliability.
Our team is available for consultations, technical reviews, and facility tours at our Union, NJ location. We invite you to experience firsthand the precision, responsiveness, and expertise that set DureX apart.
Contact Us Today
📍 DureX Inc.
5 Stahuber Ave, Union, NJ 07083, 📞 (908) 688-0800
Whether you need assistance with a prototype, a complex box build, or ongoing electro-mechanical assembly, DureX is your trusted partner for performance-driven results.
Let’s build something great—together.
