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Madrid–Villaverde PCBA Manufacturing Plant | High Reliability Electronics for Rail & Critical Industries

Precision. Reliability. Industrial Autonomy : Built in Madrid.

ACTIA Systems’ Villaverde plant is the Group’s most recent and most advanced PCBA manufacturing facility — designed to reinforce industrial autonomy, accelerate delivery, and meet the stringent quality demands of railway and critical sectors. Bringing together state‑of‑the‑art equipment, controlled processes, and deep engineering expertise, the Villaverde site ensures robust, traceable, and long‑lifecycle electronics aligned with ACTIA’s industrial excellence standards.

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Explore Capabilities
ALSTOM & CAF approved
PCBA line
3 integrated lines: SMD · THT · Conformal Coating
Advanced testing: AOI · SPI · Flying Probe · X Ray · Burn In
38,914 PCBAs/year 165 models
(target 2025)
Designed for flexibility,
small/medium series & high reliability

Key Figures & Approvals

Manufactured in the United States. Controlled. Transparent. Reliable.

0
PCBAs/year (165 references, forecast 2025)
0
machines across 3 industrial lines: SMD, THT & Coating
0 m²
fully controlled production area
0
warehouses: components & finished products
Humidity & temperature controlled zones
Dedicated workstation for external clients

Approvals & Homologations

ALSTOM:
Generic Process · PCBA coating · PCBA soldering
CAF:
full line homologation
Discuss Your Requirements

History & Milestones

2022: Business Plan Approval

ACTIA Group validates a vertical integration strategy to regain PCBA autonomy and reduce post‑COVID market constraints.

2023: Plant Start Up

  • Facility adaptation & layout preparation
  • Installation of production and test equipment
  • Recruitment of key technical teams
  • Training & production of first prototypes

2024: Homologation

Production lines approved by ALSTOM and CAF.
Controlled ramp‑up begins.

2025: Fully Operational

ACTIA consolidates all PCBA production in Villaverde; quality and operational KPIs are fully reached.

2026: Opening to External Clients

Start of manufacturing services for external customers.
Request a Plant Overview

Manufacturing Capabilities & Equipment

Screen Printing Inspection (Mycronic SPI PI PRIMO)

The Mycronic SPI PI PRIMO system guarantees exceptional solder‑paste quality through advanced 3D inspection, enabling accurate, consistent printing.
Key features:
  • Real‑time communication with the printer for automatic correction
  • 160‑Mpixel, 12‑bit CMOS camera
  • Industrial projectors, 8 HD / 10‑bit imaging This ensures precise paste volume, height control and defect prevention in the very first stage of SMD assembly.

High Speed Pick & Place Assembly (Europlacer Ineo+ 727)

The Ineo+ 727 Europlacer is designed for high‑mix, high‑precision placement of a wide range of components:
  • From 01005 miniaturized components
  • To large components up to 100 × 100 mm or 140 × 70 mm
  • Including QFN, CSP, BGA packages
  • Placement speed: up to 32,000 components/hour This machine ensures accuracy, flexibility, and excellent throughput for small and medium production series.

Controlled Reflow Soldering (BTU Pyramax Nitrogen Oven)

The BTU Pyramax reflow oven delivers stable, high‑reliability soldering thanks to:
    • 10 thermal phases
    • Nitrogen‑assisted soldering for consistent profiles
    • Maximum temperature 350°C This equipment ensures reliability and repeatability for every product’s programmed profile.

3D Optical Inspection (Mycronic AOI)

The Mycronic 3D AOI system verifies solder joints and component placement with exceptional resolution:
  • 3.5 μm in X and Y
  • 1 μm in Z Its advanced camera and software algorithms automatically detect defects such as insufficient solder, coplanarity issues or misalignment, guaranteeing flawless board quality.

Selective Soldering for THT Components (Ersa Versaflow 3/35)

The Ersa Versaflow 3/35 line provides precise, repeatable soldering for through‑hole components:
  • Flux application
  • PCB pre‑heating & drying
  • Nitrogen‑assisted selective soldering
  • Fully configurable parameters This ensures clean, reliable joints even on complex mixed‑technology assemblies.

Conformal Coating Line (PVA Delta 6)

The PVA Delta 6 automated coating machine protects PCBAs from environmental stress:
  • Moisture
  • Dust
  • Chemicals
  • Thermal cycles It provides uniform, controlled coverage via spraying, dipping, or selective dispensing — ideal for long‑lifecycle electronics.

Environment Control & Warehousing

The facility is optimized for process stability and logistics excellence:
  • Controlled humidity and temperature in all zones
  • Two dedicated warehouses (components + finished goods)
  • Secure flow of materials and optimized storage
  • Dedicated workstation for external-client programs

Test & Quality Control Area

High Precision Flying Probe Testing (Takaya APT 9411)

The Takaya APT 9411 performs:
    • Fixtureless electrical testing
    • Vision‑based component recognition (TOS 5 system)
    • Detection of missing, misoriented or incorrect components Ideal for prototypes, small series and boards with high access constraints.

Functional Testing (Bed of Nails)

This station performs full functional validation by injecting analog and digital signals. It checks:
  • Electrical behavior
  • Response under real‑world conditions
  • Operational reliability before deployment

X Ray Structural Analysis (Nordson Quadra 3 PRO)

The Nordson Quadra 3 PRO provides ultra‑high‑definition X‑ray inspection:
  • 1.6 MP resolution
  • Detection of BGA voids, QFN defects, PTH issues, cracks, counterfeit components
  • Advanced imaging software for precise structural analysis

Environmental Stress & Burn In Testing (Climatic Chamber)

The climatic chamber performs burn‑in testing under extreme conditions:
  • Temperature ramps up to 10°C/min
  • Humidity control
    • This validates robustness, stability and long‑term performance of PCBAs.
Talk to an ACTIA Engineer About Your PCBA Requirements

DfX Engineering Services

DfM · DfA · DfT

Design optimization for manufacturability, assembly efficiency and test coverage.

DfC / DfP

Cost‑ and procurement‑driven design to secure technologies and mitigate BOM risk.

DfR · DfS · DfE

Reliability, supply chain resilience and environmental impact integrated from day one.
Our Industrial Design Department develops custom test benches and oversees every stage of industrialization.
Schedule a DfX Workshop

Redesign to Deliver (R2D Program)

Why Redesign Matters

Component lifecycles are increasingly misaligned with product lifespans. Targeted redesign ensures continuity and avoids full product redevelopment.

Methodology

  • BOM risk analysis
  • Alternative components/technologies
  • Board requalification
  • Redesign aligned with supply chain resilience

Benefits

  • Faster time‑to‑market
  • Limited technical disruption
  • Secured long‑term production
  • Better lifecycle sustainability
Submit a BOM for Assessment

Industries & Use Cases

Railway

Primary focus with ALSTOM/CAF‑certified lines; suitable for traction systems, control units and onboard sub‑assemblies.

Industrial Electronics

Reliable small/medium series with full traceability and documentation.

Energy & Power Systems

Boards designed for extreme environments and demanding endurance cycles.
Validate Fit for Your Application

Villaverde: A Strategic Extension of ACTIA’s Manufacturing Capabilities

Expertise in Embedded & On Board Electronics

ACTIA Systems leverages decades of expertise in embedded electronics, developing solutions that improve safety, connectivity and sustainability across modern mobility programs worldwide.

Innovation & Flexibility at the Core

ACTIA Systems combines engineering excellence with industrial capability. Its agile structure ensures rapid adaptation to evolving market conditions, component shortages, or customer‑driven product variations. From design to integration, the company provides seamless, continuous support.

Industrial Autonomy & Total Process Control

The Villaverde plant grants ACTIA full control over the electronics manufacturing chain:
  • upstream design
  • assembly
  • integration
  • testing
  • validation & delivery
  • customer support
It provides independence for small/micro‑batch rail products and enhances competitiveness through flexibility and end‑to‑end traceability.

Continuous Improvement Culture

ACTIA Systems continuously evaluates performance, optimizes processes and fosters innovation across teams. This culture ensures consistent progress in quality and efficiency.

Quality Commitment

Quality drives every stage of production.
ACTIA Systems holds:
  • ISO 9001:2015
  • ISO 27001
  • Innovation labels for ACTiVi, Passenger Information Train Platform, Transferro, Multicarre
Audits, training and strict controls reinforce a company‑wide quality mindset.

CSR & Sustainability

CSR is central to ACTIA Systems’ strategy, reflected in:
  • support to NGOs
  • environmental responsibility
  • Agenda 2030 / SDGs alignment
  • gender equality & inclusion
  • workplace well‑being & safety
  • responsible supplier management
  • strict policies on quality, security, environment, and safety
Request a Capabilities Review

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