What Is an Electromechanical Assembly

February 26, 2022

As of 2020, the global electromechanical assembly market had a value of approximately $1.4 trillion.

Electromechanical assemblies are essential for the operation of all kinds of devices across a range of industries. But what are electromechanical assemblies? And what are their purpose?

To find out, keep reading.

What Is Electromechanical Assembly?

Electromechanical assembly is a broad term. It refers to any assemblies consisting of electrical and mechanical components or subassemblies that work together for a specific function.

These assemblies vary and will depend on the application of the final product. These assemblies are generally very complex, so are only made by skilled specialists using detailed blueprints.

Some common techniques that are involved in electromechanical assemblies include:

  • Surface mounting
  • Soldering
  • Through-hole mounting
  • Circuit layout

Due to the complexity of these assemblies, the technicians must be very precise. Many of the components are small and delicate, so a high degree of accuracy is essential.

Types of Electromechanical Assembly

The specific purpose of an electromechanical assembly will determine the components used. There is a wide range of common applications.

Switch and Sensor

Many controlling systems contain sensor assemblies and switch assemblies.

The purpose of sensors is to detect external stimuli such as motion, light, heat, or sound, and convert these into electrical signals. Typical components in a sensor assembly include:

  • Sensing elements - to detect the external stimuli
  • Transmitters - to transfer the data collected
  • Connection heads - to connect the transmitters to the sensor wires
  • Housings - to protect the sensors

Switches are to allow or stop the flow of current through a system. The typical components in a switch assembly are:

  • Contacts - to control the flow of current to and from the switch
  • Switching mechanism - used to control the device (often a pushbutton or toggle device)
  • Wiring harness - This holds the switch in place


Panels are a typical setup for electromechanical assemblies, making it easy to control the distribution of electrical power to other connected circuits. Creating these involves the following steps:

  1. Positioning components correctly on the back panel
  2. Creating holes for the components through sawing or punching
  3. Drilling holes to mount the hardware
  4. Wiring of the panel

DIN Rail

These are sometimes called mounting assemblies as they are made for mounting different components as part of an electromechanical assembly. The configuration of a DIN rail is determined by the subassemblies and components used.

Power Supply

Power supplies generate power by receiving a current and converting it into a suitable voltage and format for one or more electric loads. Sometimes these are incorporated into products, but they can also serve as standalone devices.

Some of the standard components that most power supplies are made up of include:

  • Transformer - to modify the voltage as it comes in
  • Rectifier - Convers the current from AC to DC
  • Filter - after rectification this smooths out the DC output waves
  • Regulator - reduces any ripple voltages left from the filter
  • Housing - Casing to protect the components


Transformers are integrated between circuits to transfer electrical energy between them. Different circuits may require different voltages, so a transformer will convert voltages between one or more circuits so they can work as part of one system.

Standard components in a transformer are:

  • Primary and secondary windings
  • Laminated core
  • Insulating materials
  • Application-specific tanks/accessories (such as oil conservator, cooling tubes, breather, etc.)

Cable and Harness

These are made up of wires and cables and are designed to transmit electrical signals and/or power. These assemblies generally consist of:

  • Wires and cables - to transfer the signals or power
  • Relays - to automatically switch the power on and off (for high-amperage circuits)
  • Fuses - to protect the product from any power surges
  • Connectors - connecting the components and wires to the device
  • Insulators - to protect the system if any electrical components touch each other or anything else
  • Ties - to secure the assembly to the system

Common Applications

There are many different types of electronic devices and systems that make use of electromechanical assemblies. These devices are common within several industries.


Many devices within the aerospace industry use electromechanical assemblies. They need to be compact, reliable, and very precise. A high level of quality assurance is needed for such assemblies.

These are usually custom-designed to meet exact specifications and implement particular features. Some typical examples are power boxes, lighted cockpit panels, and switch panels.


Similar to the aerospace industry, these need to be compact and precise, while allowing for specific features. They also need to be durable enough to survive the extreme environments these devices are exposed to.

Common examples in the military industry are panel assemblies and cable and harness assemblies.


One of the most important aspects of assemblies in the automotive industry is durability. Everyone wants all parts within their car to last as long as possible, so a long lifespan is crucial.

On top of this, they need to be versatile enough to meet the needs of different system requirements. Switching mechanisms, speed sensors, temperature sensors, and are some of the most common types.

Fire Protection

In the event of a fire reliable systems need to be in place to maximize safety. Systems such as fire alarms, emergency lighting, and smoke extraction fans depend on reliable assemblies to function properly.

These systems are common in many public and private spaces such as hospitals and schools. All systems need to be more fire-resistant here than in other applications.


Many agricultural devices such as tractors and combines contain electromechanical assemblies. Common types are switches and sensors, and these are often custom-designed for maximum efficiency.

Heavy Equipment

Due to the environments these are in they must be robust and reliable so they can handle harsh environments.

Common assemblies include wire harnesses, cable assemblies, and box builds.

Finding the Right Electromechanical Assembly

There are many types of electromechanical assembly, suited for a wide range of applications. All Metals Fabricating is a leading supplier of electromechanical assemblies that can be custom-built to meet your exact needs.

To find out more about what we can offer, click here to contact us today.