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Mechanical Assembly & Kitting

Floor-level execution for complex mechanical and electro-mechanical assemblies. FKI USA transforms raw stamped metals and molded plastics into fully functional sub-assemblies and retail-ready products. Operating from our 104,000 sq. ft. Carrollton, Texas facility , we are engineered for adaptive production, equipped to handle everything from simple hardware insertion to high-density electro-mechanical "Build-a-Box" integration. Read more

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Mechanical Assembly Capabilities

Our assembly floor handles production runs for a broad range of mechanical integration requirements:

  • Fastener & Hardware Insertion: PEM nuts, studs, standoffs, and threaded inserts pressed, staked, or torqued to specification.
  • Riveting & Clinching: High-speed riveting and TOX® clinching for permanent, weld-free joints on sheet metal assemblies.
  • Sub-Assembly Integration: Combining stamped metal components with machined parts, plastic moldings, gaskets, or rubber grommets into a complete sub-assembly.
  • Hinge & Latch Assembly: High-cycle mechanisms for doors, panels, and access covers requiring repeatable actuation force.
  • Structural Frame Assembly: Bolted and pinned steel frame builds for equipment chassis, enclosures, and medical cart structures.
  • Kitting & Line-Ready Packaging: Parts grouped, labeled, and packaged per your BOM and assembly line sequencing requirements.

Line-Ready Delivery

Kitting is more than putting parts in a box. Our team works to your BOM, your part numbers, and your packaging spec — so what arrives at your receiving dock goes directly to the line without sorting, counting, or repacking.

  • BOM-Based Kitting: Every kit is assembled and verified against your bill of materials before it ships.
  • Custom Dunnage & Packaging: Returnable trays, foam inserts, and custom crating designed around your part geometry and cosmetic requirements.
  • Sequence Labeling: Barcode labeling, part numbering, and lot traceability applied to packaging for direct line-side use.
  • JIT Delivery Integration: Assembled kits tied to your production schedule through VMI or Kanban replenishment.

Assembly Quality & Traceability

Assembly introduces new failure modes — torque values, press-fit forces, hardware orientation, and final dimensional confirmation. We treat assembly quality with the same rigor as our stamping processes.

  • Torque verification on all threaded fasteners
  • Press-fit force monitoring for hardware insertion
  • Visual and dimensional inspection before kitting
  • Full lot traceability from raw stamped component to finished assembly
  • ISO 9001:2015 quality management systems applied across all assembly operations

Assembly for Demanding Applications

  • Appliance: Class-A cosmetic assemblies combining stamped stainless steel with trim, seals, and decorative hardware — zero scratches, zero witness marks.
  • Medical Equipment: Structural chassis and cart assemblies built to IQ/OQ/PQ traceability standards.
  • Industrial & HVAC: Heavy-gauge frame assemblies and equipment enclosures for harsh operating environments.
  • Automotive & EV: Sub-assemblies for brackets, enclosures, and structural components requiring PPAP-backed dimensional validation.
  • Electronics: Mechanical chassis assembly and hardware kitting for server and computing infrastructure.
Industries We Serve

We carry the certifications that allow you to sell into regulated markets. Our quality lab features Zeiss CMMs for certification and Hexagon Portable Arms for reverse engineering.

Automotive and E-Mobility

EV & ICE

Coming Soon

Appliance

Turnkey Cosmetic Assemblies

Electronics & Computing

Complete Box Builds

Industrial & Heavy Equipment

Ruggedized Control Units

Aerospace & Defense

Precise. Reliable. Scalable.

Rail & Transportation

High-Tonnage Precision Stamping

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Frequently Asked Questions (FAQ)

What size products can FKI USA's assembly lines handle?

Our Carrollton, Texas facility features dedicated space for assembly, including two 10-meter moving assembly lines specifically engineered for products weighing up to 20kg. For larger or highly intricate units, we utilize stationary cellular manufacturing.

What are FKI USA's compliance standards for electro-mechanical assembly?

We operate to the highest industry standards for electronics manufacturing. Our assembly processes comply with IPC A-610 for electronic assemblies, IPC/WHMA A-620 for cable and wire harness integration, and IPC A-630 for electronic enclosures.

Can you kit products directly for retail or our JIT assembly line?

Absolutely. We provide comprehensive turnkey global logistics, including JIT implementation and customized kitting. We can package multi-component sub-assemblies with necessary hardware into single SKUs to feed directly into your inventory systems via EDI interfaces.

Accelerate Your Production Timeline

Request an Assembly & Integration Review

Stop managing siloed vendors for fabrication, hardware insertion, and final wiring. Partner with FKI USA for true floor-level execution and turnkey “Build-a-Box” manufacturing. Submit your BOM, CAD files, or prints today for a comprehensive capability review and quote.