Ericsson operates a 300,000-square-foot manufacturing site in Lewisville, Texas, where it produces highly complex circuit boards for 5G equipment. The facility, which opened in 2020, now runs continuously around the clock. Its output includes radios and other components that are shipped to mobile operators across North and South America.
The plant focuses on Massive MIMO production lines, integrating artificial intelligence, robotics, and human labor. Matt Hume, the production manager, noted that the facility creates some of the most intricate boards the company builds globally. One such board, weighing approximately 7 pounds, holds roughly 18,500 components.
This density allows the final radio-antenna unit to be smaller, lighter, and more energy efficient than earlier designs that used multiple connected boards.
Daniela Pires, who leads the USA 5G Smart Factory, emphasized the collaborative nature of the site. Engineers, software developers, and quality personnel work in the same building as the line operators. This proximity allows automation engineers to build machines directly for the operators who use them, rather than relying on theoretical specifications. Operators frequently contribute ideas that are then developed into process improvements.
The manufacturing process begins with empty, vacuum-sealed circuit boards sourced from specialized manufacturers. These boards travel along a surface mount assembly line that stretches more than 270 feet. The line utilizes nine pick-and-place machines, each capable of positioning up to 74,000 components per hour using dual heads.
The factory draws from a library of about 2,000 unique components to build customized radios for various frequency variants.
Each board passes through the assembly line twice, once for the bottom side and once for the top. Quality inspections are integrated at every stage. When solder paste is applied, cameras inspect the board immediately before components are placed.
