Custom & Modified Manufacturing

Charcroft Electronics can offer a variety of bespoke and custom packages as per our customers’ requirements. Our unique facility enables us to offer Custom Passive Assemblies, flying leads options, custom labelling and printing, ‘any quantity’ taping and reeling, in addition to optional Precision Express® manufacturing for prototype and pre-production quantities.


If you have a low volume assembly issue, challenge Charcroft to see how we can assist you. You can read more about how we have offered custom solutions for our customers’ low volume assembly problems below.


If you have a custom assembly or special project that you need a solution for, challenge Charcroft to see how we can assist you. You can read more about some of the packages we can offer below, or to read about how we have solved customer problems, take a look at our case studies.

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Our Services

Eplore the specialist custom manufacturing and modification services available from Charcroft, from passive assemblies and flying lead options to tape and reel packaging, RTD simulators and short-leadtime production support.

Strain Gage Accessories

Custom Passive Assemblies

Precision Express® Leadtime

Flying Lead Service

"Any Quantity" Tape & Reel

RTD (Resistance Temperature Detector) Simulator

Manufacturing Capabilities

  • Assembly & Production

    • Custom passive assemblies
    • Component sub-assemblies
    • Box builds
    • System builds
    • Busbar assembly
    • Heatsink attachment

  • Wiring & Harnesses

    • Electrical harness manufacture
    • Wire cutting & stripping
    • Crimping
    • Heat shrink fitting

  • Specialist Processes

    • Hand soldering (J-STD-001)
    • Epoxy encapsulation
    • Taping & reeling
    • Component screening
    • Burn-in services

  • Testing & Validation

    • Third harmonic testing
    • Component linearity testing
    • In-house testing
    • Prototype support

Featured Product

The Cliveway

Automatic Mains Selector

The Cliveway is a bespoke automatic mains selector for motorhomes, designed to safely switch between mains hook-up and inverter power.


Manufactured and assembled by Charcroft, this project showcases our capability to deliver complete electrical assemblies from prototype through to repeat production.

Case Studies

Charcroft has supported customers with a range of custom manufacturing projects, helping solve issues around obsolete components, component modification, power conversion and bespoke cable assemblies.

Component Obsolescence

Used in fluorescent light fittings where dimmer/timer control is needed and is sold as an optional extra, a capacitor/resistor assembly used in the dimmer/timer control was made obsolete by the original manufacturer, leaving the customer struggling to find a replacement. The customer was desperate to find a solution, and so they approached Charcroft to ask if we could make a replacement.



Charcroft developed a design involving a KEMET capacitor and two values of resistors made by TT Electronics (Welwyn). These were soldered together both series and parallel and encapsulated into a plastic case. Charcroft worked alongside the customer to develop a product that met their precise requirements, allowing production of the lighting control-unit to continue; we now have a regular annual order for these parts.

Component Modification

A customer had a requirement to fit insulated sleeves onto ‘snubber’ capacitors. Snubbers are used in switching circuits to reduce the voltage spikes created in switching circuits, which could result in over-voltage conditions, including arcing on the switch contacts – reducing life expectancy.


In application, the capacitor leads were exposed and technicians carrying routine maintenance ran the risk of receiving electric shocks if the leads were accidentally touched. Charcroft developed a solution to this problem, which involved fitting heat-shrink sleeving along 80% of the length of the capacitor leads.


The customer was unable to find a manufacturer capable or willing to execute the work for them, and so they then asked Charcroft to implement the manufacture of the solution for them. This involved developing and producing an automated process to handle large quantities of parts – we are now able to process 400 pieces per batch and we receive large regular requirements for these parts.

Power Conversion

Our Product Specialist made a routine visit to a material-handling customer, where the customer mentioned that they had a requirement for a power supply to charge electronic equipment on forklift trucks for the local market. Our Product Specialist was able to advise the customer that we may be able to offer a solution.


The customer then provided us with designs for two types of power supply, a 5v output device with micro USB connectivity and a 12v output version, based on the MTM PMD50 power supply. A third design covered an installation-pack to allow post-build fitment of the power supplies onto forklifts of various electrical architectures.


The designs were converted into CAD drawings by Charcroft and, following approval, samples of each design were built and submitted to the customer for testing and final approval. This allowed the customer to develop a bespoke solution suitable for the local markets or specific customers and has converted into production orders for all three lines with ongoing additional projects covering HMI systems & low-temperature operation of electronic systems.

Automotive Cable Harnessing

An automotive customer who manufactures HVAC systems for off-road vehicles had been purchasing pressure switches, resistors and thermal sensors from us, and on a support visit from a Product Specialist, it emerged that they were also looking for a cable harness supplier. After the success of the Power Conversion project we undertook, despite automotive harnesses being more complex, both our Product Specialist and Engineering Team Lead were confident that we could meet the customers requirements.


The prototype build is currently under development, and we are working closely with the customer to ensure we are meeting their exact specifications and finding solutions to any challenges that arise. The prototype stage is essentially setting out the fit and function, methods and pre-production builds for the customer, and we will be delivering the first samples shortly.

Need a Bespoke Solution?

Whether you require a modified component, replacement for an obsolete product, custom assembly or prototype build, our engineering team can help develop a solution tailored to your requirements.