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Box Build Assembly Process – What Does It Include?

by | Feb 17, 2023

The complete assembly of a customer’s end product is called ” complete box build,” also known as Systems Integration. In addition to creating Printed Circuit Boards (PCBs), the process involves the PCB fabrication of enclosures, the installation and routing of cable assemblies or wire harnesses, and the installation of sub-assemblies/individual components.

The term “box” can refer to a diverse range of assemblies, from a Printed Circuit Board Assembly (PCBA) contained in a cabinet filled with wire harnesses to a small enclosure design, or even a complex, fully integrated electromechanical assembly that involves labeling, testing, software loading, pneumatic systems, and electronics.

The global market for flexible printed circuit boards was estimated to be worth USD 12.9 billion in 2018 and is anticipated to grow at a CAGR of 11.2% over the next five years, according to a Grand View Research analysis.

Technically, Box build assembly is a complex process that involves several steps to create a final product. The process starts with the product’s design, followed by the procurement of electrical components, assembly, testing, and packaging. This article will explore the following:

  1. Advantages of using “GOOD” Box build assembly system.
  2. Vital aspects to consider in the box build assembly process.
  3. Box build assembly process and the steps involved.

Advantages Of Using “GOOD” Box Build Assembly Process

Services for box build assembly provide users with several advantages. This assembly may include additional electronics to the PCBs and pneumatic devices:

  1. Quality assurance and efficiency: 
  2. Reliable PCB box-build assembly services guarantee the job is done correctly. They focus on quality when doing their work. For more complex assembly procedures, working with the best electronic manufacturing services that perform tests to guarantee good systems integration is crucial.

  3. Lower manufacturing costs:
  4. If you employ electronic product manufacturing services, the number of wire harnesses, connectors, and tie wraps you need to buy is significantly reduced. A good box build assembly service ensures that its staff is knowledgeable about software installation and testing various build boxes.

  5. Simplify the supply chain process:
  6. Skilled box-build assembly services aim to streamline the supply chain. These services offer practical experience. They can advise you on how to make your design more efficient. Since they produce or buy cables, circuit boards, and chassis, they will lessen the complexity of your entire supply chain.

Components to consider in the box build assembly process | violintec

Key Components To Consider In Box Build Assembly Process

These are some key components to consider to get a good box-build assembly. You must give these details to your service provider:

  1. Prototype blueprint:
  2. When other information sources aren’t available, you’ll need a mockup of the box build assembly to plan a safe box build. Several equivalent assemblies can be made from a rough prototype. An expert electromechanical assembly engineer can duplicate a full box build requiring minimal documentation.

  3. Testing: 
  4. A customer must specify the types of tests an electronic manufacturing services (EMS) provider should conduct throughout the quality control procedures. Factory acceptance testing, thorough functional testing, and visual inspection are all types of test fixtures.

  5. Bills of Materials (BOM):
  6. Your EMS provider must be aware of the bill of materials, which is an essential factor. It is regarded as one of the crucial elements of the production process of box-build assembly. The BOM should include the details, including quantity manufacturer name, part type, reference designator, etc. Every item in the Bills of the component has specific details such as production process, production time, and order fulfillment time.

  7. 3D CAD packages:
  8. To see the final product more clearly, a 3D CAD model should be offered. You can pick from several CAD packages. These programs enable you to convert your drawings into build instructions and offer free drawing viewers. Making the layout drawing and managing design files with all the necessary elements is very important. The 3D CAD package tools can also speed up production time.

  9. Logistics and Shipping:
  10. You must give the electronics manufacturer crucial details about packaging and shipping. The EMS can use this information to help them choose how to handle the units. Before the production process, specify how the finished product will be packaged and shipped accordingly.

The Box Build Assembly Process

In the box build assembly process, a device is manufactured. The installation of wires and cables, the enclosure, and other components are part of the device’s creation. The size of the build box varies. The following are some of the phases in the box build’s assembly processes:

  • Design phase:
  • The design phase is the first step in the printed circuit board assembly system. It involves creating a blueprint for the product, including its dimensions, materials, and assembly process. The design team typically includes product managers, engineers, and designers who work together to create the product specifications. Once the design is complete, the team creates a bill of materials (BOM) that lists all the components needed to build the product.

  • Procurement phase:
  • The procurement phase involves purchasing all the components needed to build the product. The BOM created in the design phase is used to identify the required components. The procurement team is responsible for sourcing the components from various suppliers and ensuring they meet the required specifications. The team must also manage inventory levels to ensure no delays in the assembly process.

  • Assembly phase:
  • The assembly phase involves assembling all the components to create the finished product. The electromechanical assembly process is usually divided into two stages: Mechanical and Electrical.

    1. Mechanical Assembly:
    2. The mechanical assembly involves putting together the non-electronic components of the product. These include the chassis, casing, and other physical components. The team responsible for mechanical assembly uses specialized tools and equipment to assemble the components.

    3. Electrical Assembly:
    4. The electrical assembly integrates electronic components into the product. These include circuit boards, cables, connectors, and other electrical components. The electrical systems team is responsible for soldering the circuit board’s components and ensuring they are properly connected.

  • Testing Phase:
  • Once the assembly is complete, the product undergoes testing to ensure that it meets the required specifications. The testing phase involves several steps for PCB box build assembly, including functional testing, performance testing, and environmental testing.

    Providing Cutting – Edge Box Build Assemblies

    Accurate and comprehensive data is the backbone of any successful box-build assembly project, whether a simple or complex design. It’s the key to efficient and effective team collaboration, ensuring everyone knows what is required for order fulfillment.

    The right box-build assembly manufacturers can ease production, guarantee higher product quality, and create cost-effective assemblies.

    Introducing the best contract manufacturer Violin Technologies, at your fingertips; we augment our core competencies with strong line-leasing partnerships in electromechanical PCB Assemblies.

    Our sourcing division extends your global supply chain team along with our core capabilities. We work for you on sourcing various commodities, sub-assemblies of individual components, procurement process, qualifying suppliers, supplier audits, purchasing, stocking, devising global logistics, and delivering the products.

Almaas Saleem |author

Almaas Saleem

About the Author

Almaas Saleem is a skilled software engineer from Kerala, India who currently resides in East Africa. She is passionate about technology and constantly seeks to learn more about it through reading and hands-on experience. Almaas excels in web development, design, automated testing software, ethical hacking, cybersecurity, and digital marketing. She also works as a technical writer for new businesses, managing various entities. Almaas is distinguished by her steadfastness and commitment to her work, which consistently yields excellent results.