Jaycon Brochure

JAYCON IS AN EXTENSION TO YOUR TEAM

Or if you need, we can be your entire team, too.

Jaycon Systems is a product design, engineering, prototyping and manufacturing company that brings hardware ideas from concept to life. We are a turnkey solution for companies that want to outsource R&D and manufacturing for plastics and circuit boards. We offer an array of hardware development services that allows you to meet over 90% of your hardware needs during product development & manufacturing.

OUR PRIDE

We take pride in working with clients who have a vision. And that's because we are more than a company you outsource work to — we are your right arm and we want our work to be as impactful to their growth as it is to ours.

Our ever-evolving capabilities allow us to take on complex technological challenges, allowing our clients to focus on what they excel in. We strive to create meaningful long-term strategic partnerships with our clients so we can shape industries and impact generations to come.

LOCATIONS

Technology makes it easier than ever for companies to connect, especially when they are across the globe. It's with this technology that we continue to serve our clients, no matter where they are, as if we were local to them. And with manufacturing locations both in North America and Asia, we are able to tap into the fastest growing markets while meeting our customers' demand as they grow.

Software & Firmware

Development, Orlando, FL

Engineering & Manufacturing, Melbourne, FL

Manufacturing, Shenzhen, China

Manufacturing, Ho Chi Minh City, Vietnam

TRUSTED BY PRIME COMPANIES

TRUSTED BY PRIME COMPANIES

Companies and organizations both large and small rely on our team at Jaycon to help them innovate within their own industries. Whether their goal is to stay relevant or stand out, our clients understand the value of having a talented technology partner they can trust to get the job done effectively.

SERVICE CAPABILITIES

We are a turnkey solution for companies looking to develop hardware — whether the goal is to hire a design firm, a contract manufacturer or to outsource their R&D department completely, Jaycon is able to fill each of these needs effectively. Unlike many product design companies, Jaycon is actually able to manufacture our clients’ products. Our team is able to offset project management tasks and oversee production while our clients work on growing their business.

ENGINEERING & PRODUCT DESIGN

Mechanical & Electrical Engineering, Industrial Design, Embedded Software Engineering, and others.

PROTOTYPING

3D Printing, CNC, Resin Casting, and other rapid prototyping methods.

MANUFACTURING & TESTING

MFG: Injection molding, thermoforming, sheet metal, CNC, and more.

TEST: Drop, tensile, water absorption, UV, friction, impact, and others

ENGINEERING & PRODUCT DESIGN

At Jaycon, we take pride in translating ideas and concepts into real, innovative products that disrupt markets. Our engineers and designers work side-by-side with our clients in order to prioritize features and functionalities that are important to the early development of a product. Our expertise goes beyond design — we keep in mind long-term goals such as manufacturing, assembly costs, and time as we move through the first stages of design and prototyping.

Deliverables: CAD files & DFM proto

ENGINEERING & PRODUCT DESIGN

At Jaycon, we take pride in translating ideas and concepts into real, innovative products that disrupt markets. Our engineers and designers work side-by-side with our clients in order to prioritize features and functionalities that are important to the early development of a product. Our expertise goes beyond design — we keep in mind long-term goals such as manufacturing, assembly costs, and time as we move through the first stages of design and prototyping.

Deliverables: CAD files & DFM prototype

• Industrial Design

• Mechanical Engineering

• Circuit Board Design

• Software Engineering

• Embedded Software Design

PROTOTYPING

At Jaycon, we believe that prototyping is an art and a science — from specifying the correct tolerances and materials during the design phase, to post-processing each and every prototype we create by hand and by machine — our deliverables are as close to the real production piece as possible. We take pride in our high-quality prototypes and stand behind our work on each and every one of them.

Deliverables: Up to 100 physical prototypes

MANUFACTURING

Before going into mass production, regardless of the manufacturing method you choose, we ensure your product is designed for manufacturability — our team works with you to minimize production cost and maximize efficiency while keeping the same form and function of your product. We also guide you through the manufacturing process and help you establish a reasonable timeline and quality control system. We are also able to offer post processing services and testing, thus removing the need to work with extra companies to have a fully finished product.

INJECTION MOLDING

At Jaycon, the value added to any of our services is that we understand manufacturing from the design phase. It's no different with injection molding — we ensure your files are designed for manufacturability, while minimizing appearance of certain standard markings, such as ejector pin marks, gate marks, and parting lines. We also assist you in the choice of material and surface finish based on the product application while helping you establish a reasonable timeline and quality control system.

SECONDARY OPERATIONS

• Box-build assembly

• Electroplating

• Hydro-dipping (water transfer)

• Pad printing

• Screen printing

• Laser etching

• Overmolding

• Insert molding

• Ultrasonic Welding

• Molded in color

• Molded in symbols

Hot stamping

• Internal and external Threads

• Metal stamping

• Multiple Locations: US, China, India

• High-end equipment with ongoing improvements

• Capacity: up to 50 injection mold tooling sets per month

• Injection molding production capacity: 500,000 to 800,000 pieces per month

• Mold standards: DME (USA), Hasco (Germany) & DAIDO (Japan)

FACILITY CAPABILITIES

• Shot Capacity: fractional to 105oz

• Tolerance: +/- 0.005-0.01mm.

• Number of cavities: 1 - 16

• Mold size: miniature to automotive sized parts

• Mold weight: fractional to 14 tons

• Clamping force/ press size: 50T1000T

• Minimum thickness: 0.3-0.5mm (also determined according to different products/materials)

MATERIALS

• All thermoplastics & elastomers

• Acrylonitrile butadiene styrene (ABS)

• Polyethylene

• Polycarbonate

• Polyamide (nylon)

• High impact polystyrene

• Polypropylene

• Various textures and colors

• Precision transparent products

FEATURES & ADD-ONS

• Anti-UV

• Fire retardants

• Talc

• Antibacterial agents

• Plasticizers

• Other additives

• Chrome finish

CIRCUIT BOARD ASSEMBLY

Jaycon knows a thing or two about circuit boards — our engineers design electronics all day long while making it a goal to improve them for assembly and manufacturing. Our flexibility in manufacturing allows us to adjust production volume to align with our clients’ growth. We offer in-house prototype level assembly as well as offshore high volume assembly. We also provide value-added services so everything is done concurrently — starting from component sourcing and PCB fabrication all the way to programming, testing, packaging and shipping.

SECONDARY OPERATIONS

• Component sourcing

• PCB fabrication

• Programming

• Testing / custom test

fixtures

• Final assembly

• Packaging

TESTING

• AOI

• Manual testers

• Pass or fail indication

• Test data backup

• Visual check: video, microscope, magnifiers

• X-Ray Testing

BOARD SPECIFICATIONS

• Maximum board size: 530mm x 450mm

• Maximum board thickness: 3mm

• Minimum board thickness: 0.4mm

• Smallest chips size: 0201

• Minimum QFP pitch: 0.2mm

• Ball pitch: 0.2mm

• Maximum layers: 12

CAPABILITIES

• Vision screen printing: solder paste

• Hand forming and lead trimming

• Ultrasonic welding: plastic cases sealing

• Conformal coating: coating measurement facility

• Rework capability

• Manual tester

• Wave soldering

• Selective soldering

MOUNTING

• SMT

• Through-hole Single sided

• Double sided

• Press fits

• Mounting capability (CPH): 600,000 nominal

• Fine pitch capability

• BGA

PRODUCTION VOLUME

• Rapid prototyping

• Low and high volume

• Large production runs (largest volume client: 1M pieces)

WE LET OUR WORK SPEAK FOR ITSELF

From consumer electronics to medical devices — and a lot more in between. Jaycon has worked in several industries and understands the requirements and challenges within each segment. We have worked on products for marketing installations, medical applications, construction, entertainment, consumer electronics, space exploration, aviation, academia, automotive, environmental, and more.

VIRGIN VOYAGES WEARABLES WRISTBAND

For this award-winning product, Jaycon Systems was able to include a variety of technologies, Including RFID, in a small bracelet to be used by Virgin Voyages passengers. The band allows Sailors to unlock their cabins, make purchases, and have access to certain onboard experiences, such as casinos, VIP areas, etc. Jaycon Systems worked with Mindtribe on the industrial design but took over all the electrical design, DFM (design for manufacturing), and manufacturing, which includes yarn made from recycled ocean plastic.

Services Offered: Injection Molding, Hardware Product Design, Design for Manufacturing, Circuit Board Assembly, Circuit Board Design, Metal Casting, Mechanical Engineering, Electrical Engineering, Box Build Assembly, Circuit Board Assembly

IN-FLIGHT AHRS

This In-Flight AHRS started as a breadboard prototype the client had developed. After providing us with the firmware and a rough 3D print, Jaycon's engineering team was able to design a fully integrated circuit board and manufacturable case to be mounted onto an airplane's dashboard. The client is currently seeking private funding with his finished working prototype.

SMART THERMOMETER

For this Alexa-compatible batteryless thermometer project, the client had a semi-functional prototype that was built but not entirely ready for manufacturing. After some tweaks to their mechanical and electrical design and a full DFM check, the product was ready to undergo manufacturing to fulfill their Kickstarter campaign. Some of the services performed were injection molding, metal stamping, PCB assembly, programming, prototyping, packaging, and box build.

Services Offered: Circuit Board Assembly, Prototyping, DFM, Injection Molding, Electrical Engineering,

AR (AUGMENTED REALITY) HEADSET

The client approached Jaycon to design and manufacture a themed AR headset for an indoor kart attraction. Our team worked on the ergonomics and overall design of this 2-piece set, including mechanical engineering around the client-provided AR reflective lens. In order to comply with their strict requirements prior to mass manufacturing, a battery of tests was conducted, among them drop, scratch, bend, wash/water absorption, and others. Our team also provided to the client full circuit board design and assembly services, including firmware development.

Services Offered: Industrial Design, Mechanical Engineering, Circuit Board Assembly, Circuit Board Design, Injection Molding, Firmware Programming, Electrical Engineering, Packaging, Order Fulfillment, Box Build Assembly, Testing, Cable Assembly

COLLAPSIBLE VR GLASSES

These collapsible VR glasses were brought to life with its Lockheed Martin patented lenses. The main goal of this product was to offer a VR solution compact enough to fit into the customer's pocket for convenience, while also allowing it to be clipped onto a hat for a hands-free, headband free experience. After providing the initial industrial design sketches, Jaycon was able to take the concept and perfect it into a manufacturable solution to be injection molded. Jaycon worked with the client through the ideation, prototyping, and manufacturing phases — also being involved with the packaging and fulfillment of all orders to their Kickstarter campaign backers.

Services Offered: Design for Manufacturing, Hardware Product Design, Injection Molding, Prototyping, 3D Printing, CNC Machining

WATER-SAVING SHOWER-HEAD

After realizing the water-saving shower-heads on the market were overpriced, this client decided it was time to design a solution that was affordable. By using lightweight plastic and chrome-plating techniques, Jaycon achieved a simplified, economical, yet effective shower-head that uses less water than regular shower-heads. With the working prototype in hand, the client is on their way to raise funds for production.

Services Offered: Hardware Product Design, Prototyping, CNC Machining, Plating, Mechanical Engineering

GENERAL AVIATION FLIGHT DATA LOGGER

This general aviation flight data logger was proposed by an avid pilot who brought it to Jaycon as a rough breadboard prototype. With the work of our industrial designers and mechanical engineers, the final shape was achieved for aerodynamics and manufacturability. Combined with the client's firmware and software, thousands went into production, where Jaycon injection molded and post-processed the plastics, also fabricating and assembling the PCBs.

Services Offered: Hardware Product Design, Circuit Board Assembly, Design for Manufacturing, Injection Molding, Prototyping, Circuit Board Design, 3D Printing, CNC Machining, Circuit Board Assembly, Industrial Design

ENVIRONMENTAL DATA COLLECTOR

This environmental data collector is the successor of the client's original product. The goal of this project was to improve the original design by adding new features. After successful iterations and a round of designs, our engineering team reengineered both the plastics and the circuit board, making the entire enclosure waterproof so it can withstand weather conditions without affecting the circuit board. Jaycon proceeded with the injection molding of the enclosure and the assembly of the circuit boards.

Circuit Board Assembly, Hardware Product Design, Injection Molding, Circuit Board Design, Firmware Programming, Electrical Engineering, Mechanical Engineering, Packaging, Order Fulfillment, Box Build Assembly, Industrial Design

FORD AND GE HEALTHCARE PNEUMATIC TIMING CARTRIDGE

In response to the COVID-19 pandemic, the United States Government collaborated with Ford and GE Healthcare to manufacture 50,000 ventilators within an ambitious timeline of 100 days. As part of this effort, our team was approached to reverse engineer critical components for inside the all pneumatic ventilators.

Services Offered: Industrial Design, Mechanical Engineering, Circuit Board Assembly, Circuit Board Design, Injection Molding, Firmware, Programming, Electrical Engineering, Packaging, Order Fulfillment, Box Build Assembly, Testing, Cable Assembly

WHY JAYCON

WHY WORK WITH US?

Our team is knowledgeable, nimble, global, and takes pride in delivering quality products with quick turnaround times. Our ever-evolving capabilities and our desire to learn makes us an excellent company to partner with for product development, R&D, and manufacturing. By merging our capabilities with our clients’ vision, we get set to disrupt the markets in which our clients operate in.

We lead with learning new technologies, methods, and processes so we can provide our clients the utmost quality and competitive advantage in their industries.

QUALITY & EXPERTISE SPEED

By providing design, prototyping, and manufacturing under one company, we are able to go from idea to finished product as quickly as possible.

GLOBAL PRESENCE

We are able to tap into the fastest growing markets — giving us access to emerging technologies, excellent talent, and scalability; which may result in lower costs to our clients.

OUR GROWTH IS YOUR GROWTH

More than creating hardware, we create value. When we partner with companies that have a vision, their vision becomes ours.

The investment our clients entrust with us is spent on developing new technologies, acquiring talent, and expanding our ever-evolving capabilities to better serve them.

Since 2011, we have steadily grown our revenue, team, machine count, facility size, and service capabilities.