Secure Onshore Hi-Tech Manufacturing Services
Our state-of-the-art facility offers mission critical onshore manufacturing with advanced technology, flexible processes, and competitive pricing, ensuring high-quality products for US government agencies and their suppliers.
Hughes has over 30 years of experience in high-tech manufacturing, producing 10+ million devices and thousands of board, box, and rack-level systems for customers like OneWeb, Intelsat, and General Atomics. Our high production volume and strong vendor relationships allow us to source quality materials at competitive prices.
Our facility in Germantown, Maryland, expands our onshore manufacturing expertise to select customers, including U.S. government agencies and suppliers. With secure, domestic production, advanced technology, and a skilled, U.S.-based workforce, we ensure IP protection under U.S. law. At Hughes, we specialize in high-mix, low-volume manufacturing, offering efficient, flexible production with minimal waste and reduced lead times. Our build-to-order approach delivers high-quality products on time and at competitive prices, ensuring agility and responsiveness to customer needs.
- Close to Washington, D.C.
- 10M+ devices produced
- 30 years of experience
- Cost savings - streamlined design and production
- Quality assurance - rigorous quality controls
- Flexibility - rapid response to changing needs
- Security - US based measures protect your IP
- Peace of mind - consistent, reliable performance
Manufacturing Capabilities
Onshore outsourced manufacturing offers an excellent choice for government agencies and businesses looking to improve security, increase quality, and maintain flexibility.
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Engineering
We work closely with customers to optimize manufacturing through custom solutions, streamlined assembly, and automated testing, boosting efficiency, quality, and competitiveness.
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Prototyping
Hughes prototypes circuit card assemblies (CCAs) and integrates them into higher-level systems. Our engineers assist with design reviews to ensure reliability, while onsite testing speeds the transition from prototype to production, reducing lead times and improving efficiency.
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Fabrication
Hughes offers milling, stamping, and custom part fabrication, with expert design feedback for efficient production. Our 3D printing accelerates prototyping and proof-of-concept development.
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PCB Assembly
Hughes' multiple assembly lines handle pick-and-place for small or large runs, placing passive and active components, including BGAs and chip carriers for integrated circuits.
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Final Assembly
Hughes expertly handles final assembly, including box-level (terminals, media players) and rack-level (hardware, wiring, software) integration, delivering shipment-ready products.
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Final Test
Hughes ensures quality with experienced QC personnel and full test harness capability for board, box, and rack-level assemblies. We offer manual, automated, or hybrid testing to guarantee optimal performance.
Certifications You Can Trust
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IPC-A 610 certification (Class II and Class III)
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J-STD-001 certification (Class II and Class III)
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AS9100 certification (in process, by June 2025)
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ISO 9001 certified
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RoHS certified
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Watch the Video to Tour Our Facility
Our 400+ engineers provide expert support from design to production, optimizing products for efficiency, performance, and quality. Our collaborative approach streamlines development and enhances project success.
OneWeb utilized the Hughes manufacturing facility to build 10,000 terminals and to assemble dozens of gateway racks for shipments to remote locations around the world.
