Case Study: How Train Control Systems Achieved Scalable Growth and Production Independence

For more than 25 years, John Forsyth, founder and owner of Train Control Systems (TCS), has relied on circuit board assembly equipment sourced from a domestic manufacturer to support the design, prototyping, and production of his innovative model railroad electronics. From humble beginnings to industry recognition, Forsyth credits the manufacturer’s accessible, easy-to-use equipment with playing a central role in helping him scale production, reduce overhead, and maintain full control over his manufacturing process.

Taking Production In-House to Fuel Innovation

The LT-50 Layout Throttle designed and build in-house by TCS.

Founded in 1999, TCS first brought its digitally controlled train systems to market by outsourcing circuit board assembly, a method that quickly proved costly and inflexible. “There were delays, and no room for quick changes,” says Forsyth. “It was an obstacle for a business trying to innovate quickly.”

With the help of an SBA loan, Forsyth purchased his first pick-and-place machine from DDM Novastar, based in Southeastern PA, their benchtop model LS40. That investment marked a turning point. “We immediately gained the ability to prototype and produce in-house. That meant faster turnaround, lower costs, and full control over our production.”

A peek under the hood of the LS-60 Pick and Place machine from DDM Novastar.

Today, TCS operates two standalone model LS60 pick-and-place systems, which run nearly every day. A recent production run, for example, placed over 78,000 components using DDM equipment. The LS60 systems support TCS’s wide range of board sizes, ranging from postage-stamp to half-sheet sized boards.

“The machines are simple to learn and easy to keep running. That was critical for us in the early days, and still is,” Forsyth explains. “Setup is fast with X-Y alignment, and our feeders, mostly 8mm, are easy to change. For most jobs, we don’t even need to swap anything out thanks to our 120-position setup.”

A Complete In-House SMT Line

Beyond pick-and-place, TCS has built a complete SMT line around DDM Novastar equipment. This includes a GF12 benchtop reflow oven, selected for its compact size and ease of maintenance, and a SPR-20 manual stencil printer—the smallest in DDM’s line.

“We were using an automatic stencil printer, but the manual one actually fits our needs better,” Forsyth notes. “It saves space, and we’ve even customized it with a metal sheet from a stencil blank as the blade, which works great. It’s got full X, Y, Z, and theta adjustments, which makes setup fast.”

Long-Term Reliability and Support

Over the decades, TCS has experienced remarkably few issues with their DDM equipment. “In all this time, we’ve only had to replace one part, a flex cable assembly,” Forsyth says. “And even though we’ve upgraded models, DDM continues to support our older machines. That’s incredibly valuable.”

Now operating with a staff of about 10 employees, including engineers, production staff, and marketing, TCS continues to grow while maintaining lean, efficient operations. Forsyth, with an associate degree in electronics and extensive self-teaching, has handed off much of the circuit design to his team, but still helps run the machines when large orders come in.

LS-60 Pick and Place machine from DDM Novastar with reel feeders installed.

The Right Fit for Small and Mid-Sized Production

“Sure, there are faster machines out there,” Forsyth admits. “But they’re in a production tier too big and too complex for what we do. DDM Novastar gives us everything we need without overkill.”

For Forsyth and TCS, DDM Novastar’s equipment has provided a platform for success that combines affordability, flexibility, and a personal level of service that matches the values of a company built on craftsmanship and innovation.

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About Train Control Systems

Train Control Systems (TCS), www.tcsdcc.com , is a leading developer of digital command control (DCC) systems for model railroads. Based in Pennsylvania’s Lehigh Valley, TCS offers a wide range of electronic solutions that bring realism, control, and innovation to model train hobbyists and professionals worldwide.

About DDM Novastar

DDM Novastar, www.ddmnovastar.com , designs and manufactures PCB assembly equipment for low- to medium-volume production. Known for their robust support, intuitive interfaces, and scalable systems, DDM Novastar solutions are used globally by manufacturers who demand quality and flexibility without the need for enterprise-scale infrastructure.