Cut Away Sub AssembliesFor fifty-five years, Servometer has developed tens-of-thousands of solutions to bellows and electroform assembly challenges. For medical, military, aerospace, and other high-technology applications, Servometer offers a range of efficient precision assembly services that reduce component costs and lead-times, and sustain quality. Quantities can range from one piece to full production runs.Servometer assembly services satisfy the most stringent application requirements.

For example, Servometer assembles key parts for a precision adhesive dispenser, brazing a tungsten carbide sealing ball to a steel solenoid pin without dents, pits or flats on the shaft surface.We specialize in soldering, induction brazing, electron-beam welding and adhesive bonding for thin-walled miniature components. Evacuated assembly, hermetic sealing and back-fill operations routinely produce precision temperature and pressure sensitive devices. For a military / aerospace application, Servometer supplies fully evacuated and sealed pressure switches for oxygen regulators. The following eight summaries of our sub-assembly capabilities are an introduction to our manufacturing skills. Please review and contact us with questions.

Why Use Servometer?

  • A 55 Year History in Custom Product Design
  • Communicate Directly with Design Engineers
  • ISO 9001:2008 Certified (SGS)
  • Reduce Inventory
  • Simplify Assembly, Purchasing and Scheduling
  • Reduce Scrap Rate
  • Improve Process Control
  • Reduce Assembly Cost
  • Reduce Labor Cost
sub assembly


Servometer’s assembly personnel are experts in soldering Servometer miniature metal bellows and electroforms to custom end pieces. To avoid overheating the bellows, Servometer’s assembly experts solder using hot irons or custom hot plates, never with flame, employing time-tested proprietary processes. Our custom fixtures and assembly methods ensure high yield and lower cost. Servometer’s solder joints are leak tight and can be tested to 1 x 10-9 ccHe/sec. By practice Servometer employs only ROHS compliant solders, unless otherwise specified by your requirements.

Electron Beam Welding

Servometer’s assembly personnel are experts in electron beam (e-beam) welding of Servometer miniature metal bellows and electroforms to custom end pieces. Electron beam welding enables Servometer to weld electroformed components in leak-tight assemblies with state-of-the-art computer process control.Electron beam welding imparts only localized energy to the work piece, minimizing distortion of thin parts. It also produces exceptionally clean welds in parts that cannot tolerate contaminant. Servometer produces a precision sensor assembly for a military aerospace application by e-beam welding a bellows less than .001 thick to a stainless steel end piece. With a properly designed weld joint, Servometer can e-beam weld parts from 0.03” to 8” in diameter.

Torchless Brazing

Servometer does not usually suggest brazing electrodeposited nickel bellows to custom end pieces due to the heat involved and the difficulties protecting the bellows material from overheating. Servometer employs brazing to join sub-assembly end pieces together with a proprietary induction brazing process using a Lapel induction machine, so the pieces can be subsequently soft soldered to a bellows or an electroform.

Adhesive Bonding

Servometer specializes in close-tolerance adhesive bonding with epoxy, anaerobic or cyranoacrylate adhesives. The adhesive application area and thickness are closely controlled for cleaner, sounder assemblies.


Our computerized engraving services handle part identification and serialization for production lot control. Due to the thin walls of electrodeposited bellows and electroforms, we do not suggest that these components be serialized, but that the engraving be applied to the custom end pieces assembled to these electroformed components.

Helium Leak Testing

Our Helium Mass Spectrometer detects any leakage beyond 1 x 10-9 ccHe/sec – less than 1 cc in 32 years. Our equipment is calibrated to NIST standards.. 100% inspection ensures that a leak tight assembly is delivered every time.


Three- and five-axis computer numerically controlled (CNC) screw machines and multi-task turning centers produce the most challenging shapes to tight tolerances. Our machinists produce bellows from .020″ to 8.5″ in diameter with diametral tolerances as close as +/-0.0005″ (+/-0.013 mm). In addition to the multi-spindle machine tools, our wire electrical discharge machine (EDM) creates complex geometry using wire as small as 0.003″ diameter. All of Servometer’s precision machining capabilities are supported by state-of-the-art computer workstations hosting Pro/ENGINEER 3D design software.

Sub-Component Supply

Servometer can manufacture or procure all of the necessary sub-components for your assembly requirements, to save you the expense of handling the supply logistics yourself. Servometer will assume single-source responsibility for quality, delivery and price of the finished sub-assembly.