Secure Onshore Hi-Tech Manufacturing Services
Hughes has been a hi-tech manufacturer for more than 30 years. In that time, we have produced more than 10 million devices and thousands of rack mount systems for our own use and for customers, such as OneWeb, Intelsat, and General Atomics. Thanks to our high production volume and long-standing vendor relationships, our manufacturing team can buy cost-effective materials and components from a variety of high-quality suppliers at very competitive prices.
With our new, state-of-the-art facility in Germantown, Maryland, we are expanding our outsourced expertise to select customers—extending the benefits of our secure domestic facility, advanced manufacturing technology, skilled staff, and proven production capabilities to US government agencies and their suppliers. We provide onshore manufacturing with employees that are US citizens as well as legal, work-authorized residents. Because we are located within the United States, US law will provide protections for Intellectual Property and other proprietary data. With Hughes as your outsourcing manufacturer, you can enjoy access to advanced technology and expertise. For example, high-mix, low-volume manufacturing is a specialty at Hughes that provides our customers with many benefits.
This type of process allows for efficient production with minimal waste and the flexible processes based on your dynamic needs. This method typically requires less inventory and shorter lead times, reducing costs while maintaining exceptional quality standards. Our team has the experience and ability to ensure that our customers get the highest quality products delivered on time and at a competitive price. We take pride in providing this service as it allows us to still be agile, flexible, and responsive in meeting customer demands. Plus, with build-to-order manufacturing, we can ensure that products meet our customer expectations quickly and accurately.
Manufacturing Capabilities
Onshore outsourced manufacturing offers an excellent choice for government agencies and businesses looking to improve security, increase quality, and maintain flexibility.
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EngineeringWe collaborate with customers to deliver tailored solutions for efficient manufacturing. Our expertise in designing and implementing assembly lines and automated testing enhances productivity, reduces downtime, and improves quality. Our innovation and excellence keep our customers ahead in their competitive landscape.
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Fabrication
The Hughes manufacturing facility has the tools to perform milling and stamping to create from scratch—including custom parts. Our onsite team also has experience in design and can provide feedback to you on the most efficient and effectives ways to build your product. Our 3D printing capabilities reduces the time needed to develop prototypes and proof of concept design examples.
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PCB Assembly
With multiple assembly lines, the Hughes manufacturing facility can perform pick and place assemblies in large or small quantities, placing passive components (e.g., resistors, inductors, and capacitors) and active parts (e.g., diodes, transistors, and integrated circuits). Plus, in support of integrated circuits, we can place ball grid arrays (BGA) or chip carriers.
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Final Assembly
The experienced Hughes team can handle final assembly projects. We have experience with box level assembly, (combining existing boards and components to produce finished goods) such as terminals and media players. We also have experience with rack level assemblies that include hardware positioning, wiring, and software installation. All final assembly projects are shipment ready.
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Final Test
In addition to experienced quality control personnel in all areas of the Hughes manufacturing lines, the facility also has full test harness ability for board level, box level and full rack level assemblies. Test procedures can be manual, automated or a combination, as needed, to make sure your product performs as intended.
Engineering Optimization and Security
We have a team of over 400 engineers across various disciplines, ready to assist customers in optimizing their products during both the design phase and production. Our diverse engineering expertise allows us to provide comprehensive support, from initial concept through to final implementation. By leveraging our extensive knowledge and experience, we ensure that our customers achieve the highest efficiency, performance, and quality levels. This collaborative manufacturing approach not only streamlines the development process but also significantly enhances the overall success of our customers' projects.
We can perform final assembly, software loading, and comprehensive final testing in a secure environment that adheres to Department of Defense (DoD) standards. We execute all processes with the highest level of security and confidentiality. By maintaining strict compliance with DoD protocols, we guarantee the integrity and reliability of our services, providing our customers with peace of mind and exceptional quality. This capability uniquely positions Hughes to meet government agencies' secure, onshore manufacturing requirements.
OneWeb utilized the Hughes manufacturing facility to build 10,000 terminals and to assemble dozens of gateway racks for shipments to remote locations around the world.
Watch the video for a tour of our facility
