Custom Electronics Manufacturing for Defense & Aerospace
From circuit boards and cable systems to fully integrated assemblies, DEM designs, builds and tests mission-critical electronics for land, air, sea and unmanned programs.
- Design, engineering and manufacturing under one roof
- Prototype quantities through full production
- ITAR registered, with a 100% U.S. supply chain
Programs we support
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Our team will contact you to talk through your project. On a tight timeline? Call us at 440-564-7160.
- U.S.-Based Manufacturing
- ITAR Registered
- CAGE Code 52CQ1
- ISO 9001:2015
- IPC/WHMA-A-620
- Established in 1993
Electronics for Every Defense Domain
Pick the platform you build for and see how DEM supports it.
Ground Vehicles & Mobile Systems
Rugged electronics and interconnects that keep vehicle crews connected through vibration, shock, dust and heat.
- Vehicle radio and intercom cables
- Power and signal wire harnesses
- Rugged control electronics
- Sensor and camera interconnects
- Antenna cable assemblies
- Sealed, molded enclosures
Aircraft & Aircrew Systems
Communication and electronic assemblies for fixed-wing and rotary aircraft, including aircrew audio research funded by the U.S. Navy.
- Aircrew headset and boom microphone assemblies
- Cockpit communication cables
- Aircraft wire harnesses
- PCB assemblies for airborne equipment
- Ruggedized connectors and adapters
- Lightweight molded housings
Naval & Maritime
Waterproof, sealed electronics built for salt, spray and submersion, with ingress ratings up to IP9K.
- Waterproof and submersible cable assemblies
- Shipboard communication accessories
- Sealed connector and splice assemblies
- Rugged handheld and topside electronics
- Corrosion-resistant overmolded parts
- Custom enclosures for marine environments
Unmanned & Autonomous Systems
Lightweight, reliable electronics for unmanned aircraft, ground robots and the stations that control them.
- Payload and sensor interconnects
- Data-link radio cables
- Ground control station harnesses
- Compact, lightweight PCB assemblies
- Power distribution cables
- Prototype builds for new platforms
Soldier & Tactical Communications
Gear built for the radios soldiers, first responders and law enforcement teams already carry.
- Push-to-talk units and VPUs
- Tactical headsets and microphones
- Radio adapter and interface cables
- Body-worn power and data cables
- Rugged handheld enclosures
- Accessories configured to your spec
Radio platforms we design accessories for: Motorola, Kenwood, TrellisWare, Harris, Thales, Silvus and Persistent Systems.
Discuss Your Defense ProjectOne Partner from First Drawing to Full Production
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Everything under one roof
Design, electronics, cabling, molding, assembly and testing with one team in Newbury, Ohio. One supplier instead of several.
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Secure and compliant
ITAR registered with CAGE code 52CQ1. Sourcing, traceability and controlled technical data stay in the United States.
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Built to scale with your program
Start with a single prototype, then scale to production without changing suppliers or re-qualifying a new shop.
- 30+years building rugged electronics
- 10 weeksis all it can take to go from concept to production
- 10,000sof units per run, starting from a single prototype
- 100%U.S.-based supply chain
Full-Spectrum Electronics Manufacturing
From a single circuit board to a fully integrated, tested system. Use one capability or hand us the whole program.
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Design, Engineering & DFM
Conceptual design, product engineering and design for manufacturing, so production issues are solved before tooling.
- Clean-sheet designs or improvements to an existing product
- Concept to production in as little as 10 weeks
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Tooling & Injection Molding
Rugged enclosures and components molded in-house from tools we design and build.
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Rapid Prototyping & 3D Printing
Prototype parts and single-unit builds to prove fit and function early.
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PCB Assembly
Turnkey board assembly in a Class 100 cleanroom, from one prototype to production.
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Box Build & System Integration
Boards, cables and housings assembled, wired and tested as complete units.
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Communication & Audio Systems
Push-to-talk units, headsets, microphones and VPUs for ground, vehicle and aircrew communications.
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Cable Assemblies & Wire Harnesses
Built to IPC/WHMA-A-620, from single cables to multi-branch harnesses.
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Connectors & Overmolded Interconnects
Custom connector configurations, with electronics built into splices and housings.
Also in-house:
- Surface-mount & through-hole assembly
- Electromechanical assembly
- Overmolding
- Coiled & custom-length cables
- EMI and RFI-resistant design
- Conceptual & industrial design
- Component sourcing
- Functional testing
- Environmental testing
- Low-volume & high-mix production
Not sure what you need? Tell us about the project and we'll help you figure it out.
Tested for the Field, Built to a Standard
Ruggedness is designed in from the first decision, then proven with environmental and durability testing in-house, without waiting on outside labs.
In-house testing
- MIL-STD-810 environmental and durability
- IP ingress and submersion
- Vibration, shock and drop
- Temperature extremes, moisture and dust
- Strain relief pull and bend testing
Quality and standards
- ISO 9001:2015 quality system
- IPC/WHMA-A-620 cable and harness certification
- IPC-certified technicians
- Class 100 cleanroom for circuit boards
- In-line and final testing on every board
Developing Clearer Communications for Military Aircrew
DEM received a U.S. Navy Phase I SBIR contract award for research into noise-canceling military boom microphones. The project aims to reduce background noise while preserving speech clarity and compatibility with existing aviation helmets and communication systems.
Support at Every Stage of Your Program
Discuss
Tell us what you need and where your program stands.
Engineer
We review requirements, refine the design for manufacturing and send a plan with upfront pricing.
Prototype
We build and test prototypes until the design is ready for production.
Qualify
Environmental and durability testing in-house to prove the design holds up.
Produce
We manufacture in Ohio, from low volume to full-rate production.
Questions Defense Buyers Ask Us
Don’t see your question? Call 440-564-7160.
What kinds of defense programs do you support?
We build electronics, cable systems and integrated assemblies for land vehicles, aircraft, naval and maritime systems, unmanned platforms and soldier-worn equipment. If your program needs rugged, U.S.-built electronics, tell us about it.
Are you ITAR registered, and how do you handle controlled technical data?
Yes. DEM is ITAR registered (M47849) with CAGE code 52CQ1. Controlled technical data stays traceable from the files you send to the finished product, within a domestic chain of custody. In the Project details field, please share only a non-sensitive overview.
Do you take on low-volume and prototype work?
Yes. We build prototypes in very small quantities, including single units for validation, and production runs from a few hundred to tens of thousands of units.
How quickly can a project move from concept to production?
In as little as 10 weeks, depending on the project. We confirm the timeline with you in the plan we send after our first conversation.
Can you build to our drawings, or do you also design?
Both. We can build to your existing design or take a project from conceptual design and engineering through prototyping and production.
Can you work with the radios and connectors we already use?
Our accessories are designed for platforms from Motorola, Kenwood, TrellisWare, Harris, Thales, Silvus and Persistent Systems, and virtually any connector type and configuration can be designed and produced.
Where is manufacturing done?
At our facility at 10357 Kinsman Rd in Newbury, Ohio. Electronics manufacturing isn't outsourced offshore, and sourcing stays domestic.
Do you test to military standards?
We run MIL-STD-810 environmental and durability testing in-house, along with IP ingress and submersion, vibration, shock and temperature testing.
What happens after I submit the form?
Our team reviews your request and contacts you to talk through the project. From there, we send a project plan with upfront pricing, and you decide how to move forward.
Tell Us What You’re Building
Share your requirements and our team will follow up with a project plan and upfront pricing.