<PAGE>

                      SECURITIES AND EXCHANGE COMMISSION

                            Washington, D.C.  20549

                             ---------------------

                                   FORM 8-K

                                CURRENT REPORT

                        Pursuant to Section 13 or 15(d)
                    of the Securities Exchange Act of 1934

                             ---------------------


      Date of Report (Date of earliest event reported): DECEMBER 19, 2001
                                                        -----------------



                            ACT Manufacturing, Inc.
                            -----------------------
            (Exact name of registrant as specified in its charter)



MASSACHUSETTS                       0-25560                 04-2777507
-----------------                 -----------           ------------------
(State or other                   (Commission             (IRS Employer
jurisdiction of                   File Number)          Identification No.)
incorporation)



  2 Cabot Road, Hudson, Massachusetts                 01749
  -----------------------------------------------------------
  (Address of principal executive offices)          (Zip Code)


  Registrant's telephone number, including area code: (978) 567-4000
                                                      --------------
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ITEM 5.   OTHER EVENTS.
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On December 19, 2001, ACT Manufacturing, Inc. (the "Company") announced that it
had obtained and been operating last week under a Third Limited Waiver to its
Credit Agreement with its domestic bank syndicate, which is led by The Chase
Manhattan Bank. The limited waiver expired on December 14, 2001. The Company is
currently in default under the Credit Agreement. The domestic bank syndicate has
not agreed to any additional or extended waivers under the Credit Agreement, and
the Company has fully utilized the available liquidity under the Credit
Agreement. The Company's North American operations have very limited liquidity
at this time. While the Company continues to pursue all alternatives, the
Company has limited options available. Accordingly, the Company can provide no
assurance that it will obtain any of the liquidity that it requires or any of
the waivers or consents it requires from the domestic bank syndicate or other
parties. The Company is considering, a number of actions, including additional
layoffs at several locations and the possibility of seeking protection under the
federal Bankruptcy Act, in order to preserve its assets and value.

The information contained in the press release is incorporated herein by
reference and filed as Exhibit 99.1 hereto.


ITEM 7.  FINANCIAL STATEMENTS AND EXHIBITS.
------   ---------------------------------

(c)      Exhibit.

  99.1   Press Release dated December 19, 2001.

                                       2
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                                  SIGNATURES

 Pursuant to the requirements of the Securities Exchange Act of 1934, the
Registrant has duly caused this report to be signed on its behalf by the
undersigned hereunto duly authorized.


                                 ACT MANUFACTURING, INC.
                                 ---------------------------
                                 (Registrant)



Date: December 19, 2001          /s/ John A. Pino
                                 ----------------
                                 John A. Pino,
                                 President, Chief Executive Officer and
                                 Chairman

                                       3
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                                 EXHIBIT INDEX
                                 -------------

Exhibit                                  Sequential
Number       Description                 Page Number
-------      -----------                 -----------

99.1         Press Release dated              5
             December 19, 2001

                                       4

