In today’s product landscape, things are getting more demanding. Devices are smaller, smarter, and packed with features. At the same time, manufacturers face tighter timelines, cost pressures, and the need for agility. That’s the environment in which Flexi Versa thrives.

The Challenge: Complexity + Speed + Integration

Original equipment manufacturers (OEMs) are no longer just buying modules and assembling them—they want fully integrated systems that bring together mechanical, electrical, electronic and software elements. According to Flexi Versa, this “box build” or system‐level assembly has become a major differentiator, especially for low- to medium-volume, high-mix applications in sectors like medical, industrial automation, clean tech and semiconductor equipment.

One recent example: A global customer needed to bring a precision 3D printing system to market—complete with embedded electronics, wiring, metal structures—yet had no internal manufacturing capability. The full build had to be executed externally under tight cost and timeline constraints.

Our Approach: Vertical Integration + Close Collaboration

At Flexi Versa, the answer has been to build end-to-end capabilities that deliver everything from PCB assembly through mechanical enclosure, wiring and final system assembly. Our box build offering includes system assembly, system‐level testing (via DFT-driven design) and even clean-room environments (ISO 7/8) for sensitive build processes.

Key aspects of their approach:

• Bringing engineering on-site with the customer’s R&D team to ensure alignment between design and manufacturing — speeding decisions and reducing friction.

• Operating a “build to order” model with vertical integration across moulding, wiring, electronics, packaging – allowing faster ramp-up and lower dependency on multiple suppliers.

• Embedding testing capability early (design for test, functional test) and thinking about scale from the beginning—so prototypes can move into production without re-inventing the manufacturing base.

The Outcome: Faster Time to Market, Lower Cost, Scalability

With this model, Flexi Versa achieved impressive outcomes for their clients:

• In the 3D-printer example, New Product Introduction (NPI) was completed in just 4 weeks, combining DVT and PVT cycles.

• Cost per unit dropped to about US$100K, well below the industry benchmark of US$200K–800K for such complex systems.

• The manufacturing framework was built with scalability in mind. That meant the product could move smoothly from prototype to higher‐volume production without major redesign of manufacturing infrastructure.

• On another case (consumer audio product), beta units were delivered within six months of tool-up, and cost was contained at roughly 15 % of Retail Price — about half the typical OEM benchmark. flexiversa.com

Why This Matters

For companies designing high-complexity systems—whether in medical devices, industrial automation, IoT, or clean tech—the path from design to market often gets blocked by manufacturing’s complexity and supply chain fragmentation. Flexi Versa’s integrated box-build strategy cuts that friction by:

• Reducing the number of hand-offs and suppliers needed.

• Aligning design and manufacturing early so changes don’t cascade into delays.

• Building in test and scale from the start, avoiding rework when volumes grow.

• Lowering cost and risk because you’re not reinventing new manufacturing for each design.

Looking Forward

With markets evolving faster than ever, and with devices becoming more custom, more connected, and more regulated (especially in medical and clean-tech spaces), having a manufacturing partner who can “own” the full system build—mechanics, electronics, wiring, enclosure, test, packaging—becomes a competitive advantage. Flexi Versa positions itself to meet that demand. Their message: We don’t just assemble your modules — we build your system.

Contact us to find out more.