The electronics manufacturing industry uses various different components such as printed circuit boards, parts and cables, often from multiple vendors. To make the process simpler and more convenient, some companies providing PCB assembly services will offer full unit box build solutions, so they assemble the PCBs, other electronic components and cables in an enclosed chassis or “box”, providing a “one-stop shop” for electronics manufacturers.
What is box build assembly?
Box build assembly is one of the latter stages of manufacturing PCBs in the electronics industry, following printed circuit board fabrication and assembly. A PCB manufacturer who provides a product box build assembly will deliver a complete electronic solution, self-contained in one box. This means it’s ready to use immediately, reducing the logistical workload and potentially costs.
Some PCB manufacturers call box build assembly “system integration”, as it brings together as many components as possible into the assembly.
What components go into box build solutions?
The components included in the box build can include custom cable assemblies; wiring harnesses; connectors including D-shells and other modular connectors; batteries; heat sink attachments; other attachments to the board, such as standoffs and brackets; and attachments to the enclosure, including fans.
The designer and the assembler must work closely together to determine the requirements and how each box build assembly can be custom made. Depending on requirements, the enclosure can be made of metal or plastic. It can be machined quickly to provide cable inlets for board-mount or panel-mount connectors. Even at a moderate volume, as in hundreds of units, you’re likely to start seeing a volume discount with box build enclosures.
These are just the physical components that commonly go into an assembly. They are followed by the operating system installation, either on the device’s processor or in a memory chip.
Key steps in box build assembly
Gathering all the required components and materials for each assembly is the first step including printed circuit boards, enclosures, cables, accessories, fasteners and screws. Then, the sub-assembly of smaller modules takes place such as wire harnesses, power supplies and drives. This is followed by PCB assembly, mounting the printed circuit board and other electronic components into the enclosure using screws, standoffs or adhesives and interconnecting them with wires and cables.
Accessories such as handles, brackets and keypads are added to the enclosure and quality assurance tests are completed on the assembled unit to assure regulatory compliance, safety and functionality.
The final touches include adding items like a user manual, labelling and packaging to complete the product.
Is a box build assembly for you?
If you’re planning to use electronics manufacturing services to create a ready-to-use product, reducing logistical complications and cutting down on vendors, box build assembly could be the perfect solution.
Our services are ideal for clients in multiple industries such as audio support systems, facial recognition systems, GPS repeaters, energy monitoring systems, cabinet assemblies and more. You can have various options for enclosures, from simple plastic to custom made sheet metal enclosures.
Considering the costs and the degree of automation in box build solutions, it can be useful for moderate production runs. It’s also ideal for prototyping your design and transitioning it into production.
To learn more about our full unit box build solutions, contact our team of experts for further details.