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On this page (13 sections)
- What box build assembly covers
- Wire harness and cable assemblies
- Benefits of a single integration partner
- When to outsource box build
- Work instructions and consistency
- Harness design support
- Final test and packing
- Box build vs in-house assembly
- Industries we support
- Getting started
- Mechanical assembly details
- Labelling and compliance markings
- Traceability
What box build assembly covers
Box build, also called system integration, includes mechanical assembly of PCBs and modules into enclosures, fitting of front panels, membrane keypads and displays, mounting of power supplies, transformers and relays, internal wiring and cable routing, torque-controlled fastening, labelling and final system test.
We work with standard off-the-shelf enclosures as well as custom metal, plastic and DIN-rail housings supplied by you or sourced by us.
Wire harness and cable assemblies
Wire harnesses connect boards, sensors, actuators and power within a product or machine. We build harnesses and cable assemblies to your drawings, including crimped terminals, multi-pin connectors, heat-shrink, sleeving, labelling and continuity testing.
Harnesses can be supplied on their own or integrated directly into box build units, which removes a supplier and a handling step from your supply chain.
Benefits of a single integration partner
When the same team builds your PCBs, harnesses and final assembly, issues are caught where they start. Connector orientation, cable lengths and mounting clearances are verified during first article inspection, and changes are made once for every downstream step.
You also receive one set of quality records covering the complete unit, which simplifies traceability for industrial, medical and defence customers.
When to outsource box build
Outsourcing final assembly makes sense when your team would rather focus on design, sales and support, when your own assembly area is at capacity, or when you want one supplier responsible for the complete product. It also reduces the number of parts and sub-assemblies you need to buy, store and track.
We can take on box build for new products from the first batch, or transfer existing assembly from your facility using your work instructions and test procedures.
Work instructions and consistency
Every box build product has documented work instructions with photos, torque values, cable routing and labelling. Operators follow the same steps for every unit, and first article inspection confirms the instructions match your expectations.
When you change the design, instructions are updated and the change is recorded so that every unit can be traced to the revision it was built to.
Harness design support
If you do not yet have harness drawings, our engineers can create them from your wiring requirements. We recommend wire gauges, connector types and protection such as sleeving or heat-shrink, and produce drawings with lengths, pin-outs and labels.
Harness drawings are reviewed with you before production and become part of the controlled documentation for your product. Any later change, such as a new connector or cable length, is made through the same revision process as other product documents.
Final test and packing
Finished units are powered up and tested to your procedure, which can include functional checks, calibration verification, insulation tests and burn-in. Tested units are labelled, packed and shipped to you or directly to your customer.
Test results are recorded against serial numbers so each unit has a traceable history. Packing can include accessories, manuals and mounting hardware so the product arrives ready for installation or sale.
Box build vs in-house assembly
In-house assembly gives direct control but needs space, trained staff, tooling and inventory. Outsourcing to an experienced partner converts these fixed costs into a per-unit cost and frees your team for higher-value work.
Outsourcing also helps when demand fluctuates. Instead of hiring and training staff for peaks, you order the quantities you need and we scale production accordingly, while your team keeps focus on product development and customers.
Industries we support
Industrial controllers, test equipment, instrumentation panels, defence electronics, medical devices and vehicle electronics are typical box build products.
These products often combine electronics, electrical wiring and mechanical parts in one enclosure. Our experience across sectors means we understand the different documentation, testing and packaging expectations each industry brings.
Getting started
Send drawings, a sample unit if available, BOM and test requirements. We will quote and propose a first article build.
If you do not yet have full documentation, a sample unit and a short description of how it is assembled is often enough for us to prepare a quote and propose work instructions for your approval.
Mechanical assembly details
Box build includes fitting PCBs on standoffs, mounting heat sinks with thermal interface material, fixing transformers and relays, installing fans and filters, applying gaskets and fitting front panels and keypads. Each step is defined in work instructions and verified at first article inspection.
Torque-controlled tools and defined fastener specifications ensure consistent mechanical assembly. Critical steps, such as earthing connections or heat sink mounting, are checked and recorded during inspection.
Labelling and compliance markings
Units can carry serial labels, rating plates, safety and compliance markings and barcodes to your specification.
Labels are produced from approved artwork and checked against your specification at first article inspection. Variable data such as serial numbers and dates can be printed automatically to reduce errors.
Traceability
Each unit is linked to the PCB batches, harness batches and test results used in its assembly.
This traceability means that if a component or sub-assembly issue is discovered, affected units can be identified quickly by serial number, reducing the scope of any recall or field action.
