Custom Manufacturing & Precision Assemblies

ZZIPCO is an operating brand of Hyperion Solutions, providing contract component manufacturing, sub-assembly kitting, and custom engineering sourcing for OEMs and vertical transportation specialists.

Beyond off-the-shelf universal elevator hardware, ZZIPCO manages dedicated manufacturing programs for custom-machined items, labor-intensive sub-assemblies, and high-wear components. Supported by Hyperion’s central warehousing and fulfillment campus in Memphis, Tennessee, we offer structured safety-stock buffering based on Annual Estimated Usage (AEU) to protect your production lines from supply disruptions and raw material spikes.

Electronic & Printed Circuit Board (PCBA) Manufacturing

We support through-hole and surface-mount (SMT) printed circuit board requirements from initial design handoff through finished volume assembly, backed by 100% functional pre-shipment testing.

  • Board Types: Single-sided, double-sided, and 16+ multi-layer rigid boards.
  • Assembly Technologies: Plated through-hole (PTH), surface-mount technology (SMT), fine-pitch BGA, and mixed component placement.
  • Production Volumes: Rapid prototyping, pilot runs, and scheduled mass production releases.
  • Inventory Buffering: Staged delivery schedules with dedicated buffer stock maintained at our central Memphis warehouse for monthly releases.

Sourcing & QA Workflow:

  1. Engineering Review: Submit your Gerber files, schematics, and Bill of Materials (BOM).
  2. Quotation & Release Plan: We generate unit pricing with scheduled monthly release options.
  3. Test Fixtures & First Article Inspection (FAI): Our team works with your engineering department to review functional prints, build custom test fixtures, and supply first-article units with full QA reports for sign-off.
  4. Volume Production: Commercial production runs initiate upon purchase order confirmation and sample approval.

Turnkey Multi-Part Assemblies & Sub-Assembly Kitting

Managing multiple vendors for a single completed assembly drives up procurement costs, freight overhead, and inventory risk. ZZIPCO consolidates multi-component assemblies into a single managed part number:

  • Single-Source Assembly: We integrate plastics, CNC-machined metal, stampings, pre-wired harnesses, and fasteners into complete, field-ready sub-assemblies.
  • Custom Kitting & Packaging: Units arrive pre-assembled, inspected, bagged, and labeled to your internal bill of materials for direct installation on the line or in the field.
  • Lean Inventory Control: Eliminate the need to purchase, track, and warehouse individual sub-components from a dozen different suppliers.

Castings, Welding & Structural Fabrication

We provide precision casting, structural welding, and reverse engineering for heavy equipment, machine rooms, and transportation applications:

  • Production Processes: Die casting, sand casting, precision forging, MIG/TIG structural welding, and complex tube bending.
  • First Article Sign-Off: Every casting and structural weldment undergoes sample approval and dimensional verification against engineering prints before production begins.
  • 100% QA Inspection: Components receive comprehensive dimensional and structural inspections prior to departure, ensuring defect-free field delivery.

Precision Metal Stamping & CNC Machining

For ongoing, high-volume production requirements, ZZIPCO delivers high-tolerance stamping and machining backed by engineering review:

  • Tooling & Progressive Dies: Precision progressive die stamping, sheet metal forming, and deep drawing.
  • Print Optimization: If we identify tolerance conflicts or structural flaws in incoming CAD drawings or physical part samples, our engineering team flags opportunities for manufacturability improvements before cutting dies.
  • Reverse Engineering: Accurate reproduction of legacy, obsolete, or specialized elevator and mechanical equipment hardware to exact fit-and-function specifications.

Request an Engineering Review or Custom Quotation

To initiate an RFQ, send your 2D/3D CAD models, Gerber files, and Bill of Materials (BOM) directly to our Memphis engineering team: