A walk through Calcom Vision’s facility reveals a structured electronics manufacturing workflow that moves from design and PCB population to final assembly and packaging. With advanced SMT lines, dedicated testing zones, and specialised areas for LED products and BLDC fans, the plant is gearing up for an upcoming expansion into EV charger production.
Corporate and R&D
The headquarters houses operational planning and client coordination, while the research and development (R&D) lab functions as the design and validation centre. New product concepts are developed, prototyped, and tested here before being transferred to production lines. Engineers refine printed-circuit board (PCB) layouts, component configurations, and thermal performance parameters prior to manufacturing scale-up.
SMT lines
Surface Mount Technology (SMT) forms the first major production stage. Multiple SMT lines operate in sequence, placing components onto bare PCBs using automated pick-and-place systems. Soldering processes follow, after which boards are inspected for alignment and joint integrity.
Different lines handle varying board complexities, from standard LED driver boards to more intricate layouts. By the end of this stage, populated boards are ready for integration into larger modules.
LED sub-assembly and driver manufacturing
Once PCBs are populated, they move to sub-assembly stations. Wiring, connectors, and protective housings are added to convert boards into driver units. Operators combine automated equipment with manual fitting where required. Electrical checks are conducted before units proceed to the next stage of the workflow.
LED panel assembly and testing workflow
Driver units and LED boards are installed into panel housings along with thermal components and diffusers. Completed panels undergo illumination testing, electrical verification, and ageing under controlled conditions to assess performance stability before packaging clearance.
BLDC fan manufacturing and assembly
In a separate line, BLDC fan components are assembled and tested. Motors, controllers, and housings are integrated before the units undergo speed regulation and power-efficiency checks. Each unit is tested prior to dispatch.
Final assembly and packaging
The final assembly area integrates electronic modules with mechanical enclosures. After functional validation, approved goods move to packaging.
Calcom’s future vision
A designated area of the facility is being prepared for electric vehicle (EV) charger production, indicating an expansion into electric mobility manufacturing. The area is expected to incorporate SMT, assembly, and testing infrastructure similar to existing lines.
The expansion area illustrates the plant’s adaptability and focus on emerging markets. The company applies the same meticulous process control, workflow planning, and quality focus to new products, ensuring that future lines maintain the same operational efficiency as existing ones.
