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A DESIGN ENGINEERING FIRM THAT HAPPENS TO MANUFACTURE

ALL YOUR CONNECTOR NEEDS

ABOUT iCONN SYSTEMS

When developing new products for custom applications or enhancing existing products, designs of many electrical connectors and cable assemblies are developed to integrate standard, "off-the-shelf" products that limit design intent and product functionality.

AT iCONN, WE UNDERSTAND THAT NOT ALL APPLICATIONS ARE THE SAME, AND WE WORK WITH YOUR TEAM TO DEVELOP AND MANUFACTURE ENGINEERED SOLUTIONS FOR SPECIFIC APPLICATIONS.

FOUNDED 2006 LOMBARD, IL

iCONN Systems focuses on superior engineered product solutions, customer service, robust quality, on-time delivery and continuous improvement. 

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200+Combined Years of Connector Experience
22Number of Industries Served (and growing)
500+Product SKUS for a Variety of Applications
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SINCE ITS INCEPTION, iCONN HAS EXPERIENCED CONSISTENT GROWTH.

We’ve increased our staff from the four founding employees to approximately 100 today. iCONN continually invests in capital equipment focusing on vertical integration and adding capabilities to our existing portfolio to better service the needs of our customers.

WE’RE INVESTING IN THE FUTURE OF OUR BUSINESS WITH THE GOAL OF STEADY AND CONTROLLED GROWTH YEAR AFTER YEAR.

WE BUILD STRONG
CUSTOMER RELATIONSHIPS

We develop products for a variety of industries with a total design concept that considers application constraints, durability, ergonomics and audio and tactical features. In addition, we work with our customers to develop customized inventory stocking programs, which enables them to receive products when they need it with little to no lead time.

iCONN OFFERS IN-HOUSE CAPABILITIES THAT WILL ACCELERATE TIMELINES WITHOUT COMPROMISING QUALITY

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iCONN continues to invest in the latest technologies to improve customer experience. Our capabilities help streamline the design process and produce unparalleled prototypes. We vertically integrate around our core competencies and strive to bring capabilities in-house to reduce lead times and control our supply chain.
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  • Overmolding
  • Low-Pressure Molding
  • Component Molding
  • CNC Swiss Machining
  • Automated Soldering
  • Other Services

Overmolding

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OVERMOLDING

Overmolding bonds a layer of durable material over an existing part to form a single unit, such as joining a cable and a connector. iCONN engineers overmolded cable assemblies that comply with environmental regulations such as RoHS, REACH and Conflict Minerals at competitive pricing. Our wide variety of discrete and overmolded cables are built to meet or exceed your specifications. iCONN runs up to 40 ton presses to produce assemblies of various sizes, and utilizes thermoplastic resins such as TPU, PVC, PBT and more.

Low-Pressure Molding

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LOW-PRESSURE MOLDING

Low-pressure molding protects electronic components from moisture, dust, dirt and vibration while sealing connectors and molding grommets/strain reliefs. iCONN utilizes low-pressure molding to encapsulate sensitive components and circuitry.

Component Molding

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COMPONENT MOLDING

With iCONN’s component molding, we control our own quality and lead times. We control the whole 
manufacturing supply chain for all connector components in-house. Our component molding machines run lights-out, leveraging automated systems with robotic sprue pickers and auto feeders. Component molding automation enables us to produce quality and competitive product no matter the production volume. iCONN runs a multitude of resins, in many colors on machines up to 110 tons.

CNC Swiss Machining

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CNC SWISS MACHINING

CNC Swiss machining turns bar stock into finished components with capabilities of holding very tight tolerance. It is cost effective and provides our customers with the ability to produce low volume production runs with quick changeovers. iCONN leverages PartMaker to develop CNC machining programs and store them in an efficient manner. iCONN produces parts out of brass, stainless and aluminum on 7 axis CNC Swiss Lathes.

Automated Soldering

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AUTOMATED SOLDERING

iCONN owns two automated soldering machines, capable of attaching millions of PC mount connectors to rigid and flex circuits. By investing in automated soldering, iCONN is able to improve quality and reliability by implementing mechanical-grade precision and creating greater consistency. This technology increases engineering capabilities while not compromising quality for speed.

Other Services

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OTHER MANUFACTURING SERVICES

iCONN continually is researching new and improved ways to add automation and increase throughput on standard processes. iCONN also has the capabilities in-house to terminate any standard off-the-shelf connector, whether we make or buy it from distribution. With iCONN’s capabilities and expertise, we’re a one stop shop for our customers.

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CUSTOM ENGINEERING PROCESS AND SERVICES

Our custom engineering process takes your product from prototype to production. iCONN Systems utilizes a stage-gate model to ensure the appropriate steps and approvals are in place. Our facility and capabilities allow us to do it all in-house. We’ll work with you directly to learn your needs, then develop a strategy 
to find a cost-effective solution. Using tools like our mold flow analysis software and Part Maker, we’ll 
complete the process. Once we’re through, we provide ongoing support, such as updates or changes, as needed. iCONN leverages a unique approach to propel our engineers to the top in the industry. We don’t believe they should sit behind a computer all day— they are also trained to operate all machinery in our tool shop so they are creating the parts they design in Solidworks to assess feasibility of unique designs.

REENGINEERING/DESIGN

iCONN excels in addressing and correcting product performance and quality issues that our customers often experience with our competition. Often, we can work within our customer’s pre-existing designs to come up with value-added solutions, which can eliminate the need for a complete product redesign. Through reengineering, iCONN works with our customers to identify opportunities required to meet the specific applications, improve performance, eliminate quality and warranty claims and ultimately, reduce our customer’s costs. We strive to preserve the core features and logic, while modifying or adding functionalities that enable reverse compatibility.

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RAPID PROTOTYPING

3D printing allows iCONN to rapid prototype our customer’s concepts just hours after an initial design has been developed. While rapid prototyping provides our customers with a tangible and functional prototype, it saves the expense of non-recurring engineering (NRE) and tooling until concepts are proven. Tooling expenses alone can go into the tens of thousands of dollars; for a company with limited capital resources, this process has a huge potential upside.

iCONN can prototype parts for dimensional and fit form features; however, there are times where prototypes need to be molded out of the exact material to be used in the finished product. iCONN can make 3D printed molds, allowing us to prototype parts made from a customer’s required materials.

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CELLULAR MANUFACTURING

At iCONN, we employ cellular manufacturing, a Lean Six Sigma-inspired manufacturing process that 
assembles a product from start to finish in one production cell. This creates efficient throughput, faster cycle times and less waste.

ELECTRICAL/MECHANICAL TESTING

iCONN uses various methods for electrical and mechanical testing to ensure our products meet required specifications.

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WE 100 % ELECTRICALLY TEST EVERY ASSEMBLY WE BUILD.
  • Electrical Testing
  • FLAME Testing
  • Pull Force Testing
  • IPXX Testing
  • Thermal Cycling
Electrical-Testing

ELECTRICAL TESTING

100% electronic testing is integrated into our manufacturing process and verifies the electrical connections in a cable assembly. We document test signatures and test fixtures for every part we build. Our testers generate a unique signature based on the test fixture we build and the actual assembly we produce and ship. As part of our standard testing, cable assemblies are tested for hi-potential (hi-pot), continuity, and sequence. For more complicated cable assemblies and as required by our customers, more extensive testing can be implemented into our production process.

FLAME TESTING

The flame test verifies the connector/cable assembly’s resistance to flames. The assembly and materials must be constructed to withstand direct flame for a given time and pass NIOSH testing. Even when in direct contact with a flame, the assembly must keep the LED lit up. The flame test is critical to firefighter safety, ensuring the products have the ability to keep lifesaving equipment intact when exposed to heat and flames.

PULL FORCE TESTING

iCONN also performs pull force testing in-house to determine if the tension and breaking strength specifications have been met per regulation or contract. 

IPXX TESTING

iCONN has IPXX testing capability in-house. We test to assure there is no water ingress, whether it be from submerging the product per IP67 specifications or hi pressure testing IP69K specifications. We electrically test assemblies while they are submerged underwater.

THERMAL CYCLING

Another test iCONN conducts is thermal cycling, in which the assembly is heated to a specified temperature at a specified time and then immediately dunked into water. This test ensures all connections remain intact and water cannot enter the assembly. This test can be performed over several cycles.

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iCONN IS COMMITTED TO QUALITY

iCONN SYSTEMS IS ISO 9001:2015

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HOW WE WORK/TECHNOLOGIES

At iCONN, we believe that leveraging the newest technologies can help our customers succeed. We employ a few different tools in addition to Solidworks and AutoCAD for everyday tasks to help achieve that success.

  • Requesting Quote & Product Information
  • ERP System
  • Project management Software
  • 3D Downloads
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REQUESTING QUOTE & PRODUCT INFORMATION

To stay ahead of industry marketing trends, we host our website on Hubspot. This platform assists us in capturing new customers and aids in our efforts to take website visitors through the buyer’s journey by providing us with ways to optimize each page for SEO and user experience.  We can then classify our contact database to market relevant content to the right audience.

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ERP SYSTEM

iCONN has been using an ERP system since its inception. All of our processes are routed around the ERP system, making projects trackable and providing structure. We’re proud of our use of an ERP system because it enables us to have processes in place to manage the business, and gives us traceability into our history, which not every company has. We leverage our ERP system to streamline our processes for continual improvement, timeliness and accuracy.

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PROJECT MANAGEMENT SOFTWARE

For project management and tracking, we utilize a web-based tool called Basecamp. Basecamp keeps information about a project in one place and allows everyone on the project access to all discussions and documents.

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3D DOWNLOADS

iCONN offers our standard product as 3D downloads in a variety of formats to easily drop them into your application. This saves engineers a significant amount of time modeling connectors themselves or waiting to hear from a salesperson.  

AT iCONN, WE BELIEVE THAT LEVERAGING THE NEWEST TECHNOLOGIES CAN HELP OUR CUSTOMERS SUCCEED. WE EMPLOY A FEW DIFFERENT TOOLS IN ADDITION TO SOLIDWORKS AND AUTOCAD FOR EVERYDAY TASKS TO HELP ACHIEVE THAT SUCCESS.

HOW CAN iCONN HELP YOU ACHIEVE YOUR GOALS?