FVG delivers precision electronics, connectivity and silicone solutions for automotive OEMs.
Discuss Your ProjectIntegrated Automotive Manufacturing Solutions
Automotive Applications
FVG manufactures electronic, interconnect and elastomer components for critical automotive systems.
Engine & Powertrain
Reliable electronic and interconnect solutions for engine, transmission and powertrain systems, designed to withstand demanding automotive operating environments.
Body Electronics
PCBA, wire harness and component assembly solutions for body control systems, including vehicle access, comfort, safety and convenience functions.
Door & Roof Systems
Precision components and assemblies for power windows, door controls, sunroofs and roof systems, combining reliable electronics with durable sealing and tactile components.
Instrument Panels & HMI
Electronic assemblies and silicone-based components for instrument clusters, switches, keypads and human-machine interfaces, supporting reliable driver interaction.
Sensors & Control Modules
Manufacturing support for sensor assemblies and electronic control modules, including PCBA, interconnects and precision component integration.
Lighting & Tow Systems
Reliable electronic and interconnect solutions for vehicle lighting, trailer and towing systems, supporting consistent performance across demanding automotive applications.
Manufacturing services
Three disciplines, one factory floor.
The exploded assembly above is not simply a visual representation—it reflects FVG’s actual manufacturing and integration capabilities. FVG manufactures the printed circuit board assemblies (PCBAs), wire harnesses, and precision-moulded silicone/LSR components that work together behind the switch panel and trailer lamp. Rather than supplying these components separately, FVG can bring them together through integrated module assembly, including controlled assembly, sealing and end-of-line testing. This allows OEMs to consolidate multiple manufacturing processes under one partner, improve component compatibility and traceability, simplify supplier management, and receive a fully assembled, tested and ship-ready module built to their specifications.
Integrated Electronics Manufacturing
FVG brings together PCBA, wire harnesses, and silicone/LSR components into one integrated manufacturing solution. From SMT assembly, coating, ICT/FCT and functional testing to precision crimping, CFM and 100% electrical testing, every component is manufactured and verified to meet your product requirements.
Integrated Module Assembly
Beyond individual components, FVG provides complete module integration—assembling, sealing and end-of-line testing the finished unit. This reduces supplier complexity, improves traceability and gives OEMs a single manufacturing partner responsible for the complete module.
Ship-Ready, Customer-Specific Delivery
Finished modules are delivered ship-ready and built to your standards, with labelled units, customer-specific packaging, UID genealogy and ERP-generated ASN. With one PPAP, one UID and one genealogy chain, FVG simplifies quality documentation, traceability and logistics from production through delivery.
Our Capabilities
PCBA, Wire Harness and Silicone Manufacturing Capabilities
We bring together advanced manufacturing capabilities to meet the evolving demands of high-performance PCBAs, wire harnesses and silicone components for the automotive industry. Our expertise spans PCB assembly, wire and harness engineering, and elastomer moulding, ensuring quality, consistency and speed at scale. With a strong focus on durability, IATF 16949 compliance and product lifecycle efficiency, we support customers in bringing reliable vehicle electronics to market. Whether for a single-circuit sensor lead, a multi-circuit harness terminating directly onto a PCBA, or the moulded silicone keypad and seal that complete the module, our approach is built on control, transparency and traceable execution.
Electronics - PCBA & Electronic Module Assembly
Placement, Reflow and Through-Hole Assembly
Surface-mount and mixed-technology assembly from 0201 chip components through fine-pitch QFN and BGA packages, connectors and odd-form parts, plus selective solder, wave solder, press-fit and certified hand-solder rework — built to IPC-A-610 Class 2 or Class 3 and soldered to J-STD-001.
Inspection and Test
Solder-paste inspection, pre- and post-reflow AOI, X-ray for BGA void analysis, ICT / flying probe, functional and end-of-line test, boundary scan, burn-in and run-in — every result captured against the unit serial.
Environmental Protection
Selective conformal coating, potting, gap-fill and thermal-interface application for underhood and exterior-duty modules, with MSL floor-life tracking and an ESD program to ANSI/ESD S20.20.
Interconnect - Wire Harness & Cable Assembly
UL-Verified Wire and Terminal Selection
Every circuit starts from verified wire styles, current ratings and compatible terminals matched to the voltage, temperature and flame-performance needs of the application.
Precision Crimping and Termination
Automatic and semi-automatic cut, strip and crimp with crimp-force monitoring on every terminal, pull-force testing, crimp-height measurement and cross-section micrographs to a defined sampling plan.
Custom Harness Design, Routing and Test
Multi-circuit routing, connector termination, shielding and strain relief for sensor and body circuits, sealed and unsealed connector systems including 7-way tow connectors, and 100% continuity, short/open, polarity and hipot testing — inspected to IPC/WHMA-A-620.
Elastomer - Silicone Rubber & LSR Moulding
Moulding, Tooling and Multi-Material Overmoulding
LSR injection and HCR compression / transfer moulding with in-house tool design, plus two-shot and insert overmoulding of silicone to plastic, metal and PCB carriers — including backlit keypads with laser-etched legends and integrated light guides.
Sealing and Environmental Duty
Gaskets, grommets, boots, bellows, strain reliefs and cable overmoulds for IP-rated joints, rated for typical service from −50°C to +200°C with low compression set and strong UV / ozone resistance.
Dimensional and Functional Validation
Dimensional inspection, force-travel curve capture and actuation-life testing, with post-cure verified to spec on every batch.
How We Control Our Quality
Automotive-Grade Quality & Reliability
Our manufacturing processes are aligned with IATF 16949 automotive quality requirements and supported by IPC-A-610, IPC/WHMA-A-620 and J-STD-001 standards. We apply 100% electrical testing, AOI/X-ray, ICT/FCT, full traceability and product genealogy, together with strict MSL and ESD controls to ensure consistent quality, reliability and customer-ready integrated modules.
IATF 16949
Our quality management system follows IATF 16949 automotive requirements, focusing on defect prevention, process consistency, risk management, and continuous improvement to deliver reliable automotive components and modules.
IPC-A-610
IPC-A-610 defines the workmanship and acceptance criteria for electronic assemblies, ensuring PCBA soldering, component placement, cleanliness, and assembly quality meet recognized industry standards.
IPC/WHMA-A-620
IPC/WHMA-A-620 provides quality requirements for wire and cable harness assemblies, covering crimping, terminals, connectors, insulation, routing, and overall workmanship.
100% Electrical Testing
Every applicable assembly undergoes 100% electrical testing to verify continuity, connections, polarity, resistance, insulation, and other defined electrical parameters before shipment.
AOI / X-ray
AOI and X-ray inspection provide automated and non-destructive inspection of PCBAs, detecting visible and hidden defects such as component placement issues, solder defects, voids, and BGA-related problems.
ICT / FCT
ICT and FCT verify both circuit integrity and product functionality. ICT checks the assembled circuit, while FCT confirms the completed product performs according to its intended specifications.
Traceability
Our traceability system links materials, components, production processes, operators, inspection results, and test data to the finished product, enabling complete product history and genealogy when required.
MSL Control
Moisture Sensitivity Level (MSL) control protects moisture-sensitive electronic components through controlled storage, handling, exposure-time monitoring, and appropriate drying processes to prevent moisture-related defects.
ESD Control
Our ESD-controlled manufacturing environment protects sensitive electronic components from electrostatic discharge through grounded workstations, ESD-safe equipment and packaging, personnel controls, and regular monitoring.
Tier-1 & Tier-2 automotive build partner
Tier-1 & Tier-2 automotive build partner
Every switch, harness and seal — from one supply chain.
FVG builds the electronics, the wiring and the silicone that go inside North American passenger cars and the trailers they tow — assembled, tested and traced under one IATF 16949 quality system.
Vehicles are becoming more instrumented, more electrified and more dependent on real-time sensor data. This shift demands PCBAs, wire harnesses and sealing components that balance signal integrity with long-term durability, vibration resistance and electrical reliability in demanding on-road and off-road conditions — and the trailers those vehicles tow, which carry a second lighting and interconnect system of their own. Our vertically integrated model brings PCBA assembly, wire harness manufacturing and silicone moulding together on one factory floor, so the interface between them is resolved as an internal drawing rather than managed across separate suppliers. From design through development and delivery, we make sure the switch modules, sensor harnesses and silicone parts powering critical vehicle systems meet strict dimensional tolerances, withstand demanding thermal and vibration conditions, and deliver consistent electrical performance — because our success depends on our customers' success in their products.
FAQs
Frequently Asked Questions
Does Flexi Versa Group provide wire harness manufacturing?
Yes. At Flexi Versa Group, we manufacture wire and sensor harnesses requiring verified wire and terminal selection, controlled crimping, and precise electrical performance for automotive and heavy-duty vehicle applications.
Can Flexi Versa Group integrate wire harnesses directly with PCBAs?
Yes. We provide manufacturing solutions for harnesses engineered for direct integration onto PCBAs, including connector compatibility, signal testing and functional validation.
What types of automotive modules does Flexi Versa Group manufacture?
Our capabilities include console and body switch modules, sensor and body harnesses, sealed trailer lighting and tow interfaces, and backlit silicone keypads and sealing components.
Can Flexi Versa Group mould the silicone components that pair with its PCBAs and harnesses?
Yes. We manufacture LSR-injected and HCR-moulded keypads, seals and gaskets, including two-shot overmoulding, in the same facility as the PCBA and harness lines they pair with.
Can Flexi Versa Group support low-volume, high-mix production?
Yes. Our flexible manufacturing capabilities support specialised PCBAs, harnesses and silicone components for evolving production requirements.
Why does quality-system certification matter for automotive PCBA and harness work?
IATF 16949 certification confirms that wire, terminals, PCB assembly processes and moulding methods meet applicable safety, voltage and temperature requirements — reducing the risk of qualification delays, redesigns and compliance issues during production.
How does Flexi Versa Group ensure traceability for PCBAs, harnesses and silicone parts?
At Flexi Versa Group, we implement unit serialisation, quality validation testing and manufacturing process controls aligned to IPC-1782 to provide end-to-end traceability throughout the product lifecycle.
Can Flexi Versa Group support high-vibration and high-temperature environments?
Yes. We manufacture harnesses and silicone components engineered for vibration resistance and high-temperature environments, including engine-bay, exhaust and chassis-mounted applications.
Does Flexi Versa Group support signal integrity testing between the harness and the PCBA?
Yes. We test completed harnesses and PCBAs together — including continuity, insulation resistance and functional testing — to confirm accurate signal transmission.
How does Flexi Versa Group help manufacturers scale from prototype to production?
We combine PCBA assembly, wire harness manufacturing, silicone moulding, testing and supply chain management capabilities to help manufacturers transition efficiently from development and validation stages to scalable production.