Box Build Assembly – What you need to know
What is a Box Build Assembly?
Box Build Assembly (aka “systems integration”) is a complete integrated system. A printed circuit board (PCB) is built and enclosed complete with cables, din rail, backplane assembly, cabinet housing, and other essentials. The box build assembly involves everything… including design, production, and construction.
Box Build Assembly services can include:
- Design and Engineering
- Software and Product Configuration
- System level assembly
- Sub-level product assembly
- Product Assembly
- Software installation
- Product configuration
- Full System Testing
- Packaging and/or Shipping
- Labeling
- Warehousing
- Order fulfillment
- After-market service
- Repair
The box build process itself is specific to each project and varies based on design requirements.
Advantages of Box Build Assembly
A box build assembly brings advantages.
- Potential for a faster turnaround
- Reduction in manufacturing costs
- Higher quality
- Simplifies supply chain
Electromechanical services that assemble an array of products will be more familiar with each component mounted in the box build. You can reduce shipping timelines, streamline your assembly process, and lower costs while maintaining high-quality. Often it eliminates miscommunication because you don’t need to contact several vendors about changes. If your box build is built by one vendor, the individual components, such as the circuit boards and wire harnesses, will be built to work together.
Considerations for Your Box Build
Here are some basic considerations to ensure success of your box build assembly.
Dimensions
The electronic manufacturing services company must know the dimensions of your finished product, and its appearance. Supply design drawings with tolerance and clearances clearly labeled. Provide the size and weight of the finished unit in advanced. This is helpful to production, storage, and shipping.
Bill of Materials (BOM)
Provide your electronic manufacturing services company a detailed Bill of Materials (BOM) listing all components and materials needed. Details are important and helpful. Clearly state where the source of the materials, what you will provide, and what electronic manufacturing services company will provide.
Prototype
Electronic manufacturing services with an in-house prototyping can provide key information for design and function testing. This can be done prior to production to identify changes needed before assembly begins.
Testing
Provide your electronic manufacturing services company of specific tests required during assembly and on the final product. Many times, a visual inspection is satisfactory, but functional thresholds may need to be met (and tested). Be sure to communicate with your assembler so they are aware of any required electrical and functional testing.
To avoid a long list of questions and multiple meetings to understand your needs, provide as much information as possible.
The Process for Box Build Assemblies
Typically, a box build will contain printed circuit board assemblies (PCBAs), wire harnesses, point-to-point wiring, and the mechanical structure of the box. Building all of this together is similar to making a cake, with multiple layers. The order and structure of the pieces is critical to the success of the project.
- Build and test all printed circuit board assemblies used in the device.
- Build and test all device cables and wire harnesses.
- Cut, strip, and label the ends of individual wires in preparation for assembly.
- Start the assembly of the box build from the bottom. Work up through each level. This includes bolting parts together, seating and interconnecting circuit boards, and connecting wire harnesses and point to point wiring.
- Incorporate customer manufacturing specifications into each level. Inspect each level for:
- Required labels
- Wire routing
- Screws with critical torque specifications
- Continuity test points.
- Conduct a final inspection prior to installing the covers of the assembly.
- Test the device
- Record the results.
Simple box builds final test results may be a PASS/FAIL. A contract manufacturer focused on quality will collect more information and develop a more comprehensive test procedure.
Box Build Assembly – A complete manufacturing solution
Custom Interface, Inc. provides a total manufacturing solution. We apply our AS9100 compliant processes to source, purchase and manage the supply chain for new products and mature production builds. Our team:
- Inspects customer facing exteriors to the highest cosmetic standards
- Assembles to customer approved documented processes
- Test and burn-in per specification
- Ship equipment to locations of your choice
We collaborate with our mechanical component partners to find the right solutions for your designs at the lowest costs and the shortest lead times.
We are currently delivering panels and boxes to customers in:
- Aerospace
- Communications
- Test and measurement
- Industrial controls.
You will no longer have concerns about managing information, specifications, parts, and materials between vendors. We will manage these details for you. We will not make changes in your documentation without contacting you. Your final box build will have a full and accurate “as-built” set of documentation so you can track the true and current built state of your device.
Questions? Need more information? Take a moment to contact us here.