Manufacturing

Sealevel’s production and manufacturing lines are affectionately referred to as “where the rubber meets the road.” By employing state-of-the-art equipment and a skilled American workforce, we are able to scale as needed to meet customer requirements.

We are committed to the design and manufacturing of quality critical communications hardware and software, dedicated to providing reliable products, exceptional service and on-time delivery. Our commitment is further demonstrated by our ISO 9001:2015 certification and extensive on-site testing capabilities. Every Sealevel product is American-made and tested to exceed requirements. Sealevel’s team of engineers and manufacturing technicians has experience designing and manufacturing for various military and commercial standards including MIL-STD-810, MIL-STD-461, MIL-STD-1472, MIL-STD-901, MIL-STD-464, MIL-STD-167-1, UL, CSA, FCC, CE, NEMA, IP, ATEX, CID1 and CID2.

Manufacturing Capabilities

With a “design for certification” approach, Sealevel’s manufacturing and engineering teams collaborate closely from concept to official production. Sealevel manages the entire product development, manufacturing, testing and packaging cycle. Our Electronic Design & Manufacturing Services (EDMS) are available for projects ranging from turnkey design and production to quality assembly of your own design.

Printed Circuit Board Assembly

Our printed circuit board assembly process is driven by a state-of-the-art Surface Mount Technology (SMT) line. Sealevel employs methods for defect tracking and trending, route verification, feeder verification and real-time process alarming. Electrostatic Discharge Controls (ESD) and Moisture Sensitive Controls (MSD) are in place throughout the facility.

Through Hole Assembly

Our in-house team of solder technicians is J-STD-001 Certified and IPC-A-610 Certified. Following through hole assembly, boards are cleaned via our inline aqueous cleaner.

Board Level Test

Full functional testing is completed on all Sealevel standard I/O and computing products. Custom test plans are developed in partnership with customers to facilitate optimal field performance. Our on-site x-ray, vibration and thermal test equipment enable pre-certification testing.

Box Build Assembly

Sealevel’s automated conformal coating equipment allows for accurate, defect-free conformal coating and protection of electronics. For assembly, technicians follow comprehensive procedures for product building, labeling and modification.

Special Projects Area

Within Sealevel’s 52,000 square foot facility, there is a dedicated space for the manufacturing and test of high-profile projects. This space allows for enhanced physical security as required and is configurable to meet product specifications, ensuring optimal production for OEMs.

Finished Goods Inventory

Sealevel maintains dedicated warehouse space to allocate for custom project storage. Standard I/O and computing products are replenished in accordance with product lifecycle management.

Shipping

Standard shipping configurations include reinforced enclosures as well as ESD foam and materials. Sealevel’s shipping team completes a detailed packaging evaluation for all products – standard and custom – oftentimes partnering with OEMs to meet their requirements.

Equipment

All board-level assembly and testing take place at Sealevel using our state-of-the-art surface mount manufacturing line. All products are visually screened using Automated Optical Inspection (AOI) and 100% of the functionality is tested before shipment.

Automated Screen Printer with 2D Inspection
30-Spindle High Speed SMT (34,500 CPH Placement)
7-Spindle High Speed SMT (16,500 CPH Placement)
7-Spindle High Speed SMT (16,500 CPH Placement)
Ten Zone Forced Convection Reflow Oven
5-Camera Automated Optical Inspection
Closed-Loop Inline Aqueous Cleaner with Isolation
Multi-Angle Transmissive X-Ray
2-Axis Vibration Table
Thermal Walk-In Chambers
Automated Conformal Coating

  • All processes are completed under ISO 9001:2015 and internal quality standards to ensure product reliability and reduce field failure rates.

  • Sealevel’s standard security procedures include practices as outlined by CMMC and NIST 800-171. Our staff and facility are also equipped to meet specific customer requirements.

  • Comprehensive test plans for all hardware and software products are developed in conjunction with Sealevel’s test and compliance engineers.

  • Sealevel was founded with a commitment to long-term availability and continues to build and support products for the life of your project.

  • Our engineering, master planning, manufacturing and procurement teams work together to maintain long-term access to components and manage our inventory accordingly.

Our Location

Sealevel was founded in 1986 with a commitment to American labor: Our manufacturing facility is co-located with our headquarters in Liberty, South Carolina. Unlike competitors, Sealevel has never relocated manufacturing outside of the USA, maintaining our rigorous control and quality standards.

More than a Manufacturer

Sealevel delivers over 35 years of precision engineering design, system integration and comprehensive testing. Whether you need a turnkey design from concept to production or quality assembly, talk to the team that’s more than a manufacturer.

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