Automotive Tier-1 Automotive Supplier — Body Control Module Volume Ramp
A Tier-1 automotive supplier moved a body control module from a low-volume prototype vendor to production-scale supply under IATF 16949.
- Layers
- 6
- Volume
- 240,000 units/year
Aerospace Instrumentation
Aerospace Instrumentation Supplier — Legacy Board Requalification
An aerospace instrumentation supplier requalified a discontinued 12-layer board design after its original manufacturer exited the market.
- Industry
- Aerospace Instrumentation
- Layer Count
- 12
- Production Volume
- 1,200 units/year
Challenge
An aerospace instrumentation supplier's original board manufacturer exited the PCB fabrication business, leaving a qualified 12-layer instrumentation board with no active source. The board's original materials and processes needed to be matched closely enough to avoid retriggering a full instrument-level requalification.
Approach
Copperline's engineering team reverse-documented the original stack-up from archived fabrication drawings and matched available materials as closely as possible to the original specification, flagging the small number of substitutions that couldn't be matched exactly for the customer's engineering team to review and approve before production began.
Outcome
The requalified board passed the supplier's incoming inspection and functional test criteria against the original acceptance limits, restoring supply for a low-volume, long-lifecycle program now running at 1,200 units/year with Copperline as the qualified source of record.
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More Case Studies
Other programs, other industries.
Automotive 
Consumer Electronics Consumer Electronics Brand — Prototype-to-Volume Transition
A consumer electronics brand needed a single manufacturing partner to carry a product from low-volume launch through mainstream retail volume.
- Layers
- 4
- Volume
- 85,000 units/year
Medical Device Class II Diagnostic Device — Sensor Board Requalification
A Class II diagnostic device maker requalified a failing sensor board line without slipping a regulatory-locked launch date.
- Layers
- 8
- Volume
- 18,000 units/year