Flex Box Controllers

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  • There is a significant volume opportunity to remanufacture this design of control unit.
  • Determine a process to open an ECU housing designed to not be opened.
  • Open the flexed printed circuit board without breaking the board or solder connections.
  • Develop a ruggedized reman process for the product.


  • After the reman process, the unit must function as good as a new unit.
  • The PCBA must be flexed closed without damage after repairs.
  • The ECU must be air tight to customer specifications.
  • The end result needs to be a cost effective reliable alternative to new.
  • Discover failure modes through extensive testing, hot , cold, and room temperature.


  • We determined a process to cut open the housing to gain access to the PCBA.
  • There is a maximum angle the PCBA can be opened without damage to the board itself.
  • A block was designed to keep the board from flexing beyond or below a specified angle. Ciona has determined that the flex circuit board within the flex box can be damaged by over-flexing or multiple flexes, much like any wire so we have elected to only a unit to be opened and closed one time to reduce the risk of damage to the board.
  • A primary failure was discovered and the OEM notified for future production.
  • New internal housings are utilized and provide the best opportunity to meet the air pressure specification.


  • This process covers a broad range of part numbers and applications from Agriculture, Marine, and Construction.
  • Discovered failures from testing reported back to the OEM.
  • A ruggedized remanufactured product is designed to minimize downtime and provide the customer a lower cost repair alternative.
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