Black Foundry is building a vertically integrated electronics manufacturing platform — purpose-built for defense primes, OEMs, DOD programs, and satellite communications, and the niche technologies others can't build. From 80,000 sq ft today to a planned 550,000 sq ft at full build-out — in-house North American manufacturing capacity backed by a global PCB network.
Five capabilities, vertically integrated and AI-instrumented — eliminating the handoffs, lead-time stack-ups, and quality escapes of a fragmented supply chain.
Bare-board supply through a qualified global fabrication network — rigid, rigid-flex, HDI, and RF substrates.
High-mix SMT and through-hole assembly with AOI, X-ray, and full traceability — built to IPC Class 3 workmanship.
Higher-level assembly, cable and harness, conformal coat, potting, and functional test — shipped deployment-ready.
Enclosures, chassis, machining, and thermal solutions integrated directly with the electronics build.
DFM/DFT engineering, layout, and NPI support — designs hardened for manufacture before the first article.
Custom cable, harness, and interconnect assembly built and tested alongside the systems they serve.
Functional test, environmental stress screening, and burn-in — verified performance before hardware ships.
AI-driven sourcing, component intelligence, and in-house North American supply management with full traceability.
Black Foundry is being built from day one around defense and satellite communications hardware — not retrofitted for it. High-reliability process discipline, secure workflows, and a compliance roadmap designed for prime and sub-tier defense supply.
Black Foundry is building dedicated sub-tier capacity for primes and OEMs: program-dedicated production cells, DFARS flow-down readiness, full lot traceability, and in-house North American manufacturing capacity with surge-ready scale to 550,000 sq ft — a domestic supply partner engineered to de-risk your program, not add to it.
Sub-tier and prime-support manufacturing for ground, air, and maritime systems — low-volume, high-mix, zero-defect expectations.
SATCOM ground segment and space-adjacent hardware: RF front ends, modems, antenna electronics, and ruggedized terminal assemblies.
Controlled-impedance builds on PTFE and hybrid stack-ups, with process control tuned for high-frequency performance through Ka-band.
Segregated data environments, controlled access, and domestic-only build paths for export-controlled and sensitive programs.
Our sweet spot is the hard stuff — exotic materials, extreme environments, and low-volume, high-consequence builds where process discipline is the product.
Microvia, stacked-via, and rigid-flex constructions for dense avionics and space-constrained terminal hardware.
Rogers, PTFE, and hybrid stack-ups with controlled impedance and repeatable high-frequency performance.
IPC Class 3 / space-addendum workmanship for mission-critical and life-of-program hardware.
Conformal coat, potting, staking, and environmental sealing for shock, vibration, and thermal extremes.
Metal-core and heavy-copper boards with integrated mechanical thermal management for high-power RF and power electronics.
Fast-turn prototypes to qualified production — one accountable partner from first article to fielded unit.
DOD certified electronic components manufacturing and supply chain — qualified parts, authorized sourcing, counterfeit mitigation, and full chain-of-custody traceability from raw material to fielded system.
Time to market is a weapon. Black Foundry compresses the path from design release to fielded hardware — quick-turn builds, parallelized NPI, and expedited production lanes that keep your program schedule, not ours.
Prototype and first-article builds in days, not weeks — with production-grade process control from the first board.
DFM, sourcing, tooling, and test development run concurrently — cutting weeks out of every new product introduction.
Dedicated quick-turn capacity that never queues behind volume production — for urgent program and fielded-system demands.
AI-driven demand sensing and strategic component inventory positioned ahead of the build.
Same lines, same quality system, same data — no requalification penalty when you scale.
Live build status, test data, and delivery tracking — no chasing your CM for updates.
Capacity is being built ahead of demand — a phased campus plan that scales the footprint 6.9× without ever moving your program.
Chicago flagship facility. SMT lines, box build, mechanical integration, and NPI engineering under one roof.
Expanded assembly capacity, test and environmental screening, and dedicated secure production cells for defense programs.
6.9× campus scale: high-volume capability, deeper vertical integration, and program-dedicated capacity for defense primes and OEMs.
Bare-board supply is the most common failure point in electronics programs. Black Foundry manages it as a core capability: in-house North American manufacturing capacity for assembly, integration, and test — augmented by a qualified global PCB fabrication network for cost and capacity, with domestic-only fabrication paths for ITAR-sensitive and export-controlled work.
In-house assembly, integration, and test across a North American supply base — capacity you control, on this continent.
US-based fabrication routing for controlled, sensitive, and defense-rated programs.
One supplier, one quality system, one throat to choke — from bare board to box build.
Predictive lead-time, cost, and risk modeling across the network before you commit a build.
Every Black Foundry capability runs on a single secure AI operating layer — connecting quote, design, supply chain, factory floor, test, and delivery into one intelligence loop. It's how the platform grows efficiently: capacity scales 6.9×, overhead doesn't.
AI-assisted quoting, DFM analysis, and risk scoring at intake — accurate commitments before the PO, not after.
Machine-level telemetry, predictive scheduling, and yield analytics driving continuous throughput and first-pass-yield gains.
Predictive lead-time, cost, and shortage modeling across the network — risk surfaced before it hits your build.
Inspection, test, and field data fed back into process control — every build makes the next one better.
Segregated enclaves, role-based access, and controlled data flows engineered for ITAR and CUI environments.
The layer that lets 80,000 sq ft run like a startup — and 550,000 sq ft run like 80,000.
Full site, capability details, and program onboarding are on the way. Reach out now for early partnership, RFQs, or facility conversations.