Here’s how to identify the right box-build assembly manufacturer!

The Electronics box build is precisely constructed to meet a PCB product’s design requirements and safety standards. They include one or more printed circuit board assemblies, interconnecting cables, user interfaces, and other sub-assemblies in a well-fitted box. Many contract manufacturers provide box-build assembly services like system-level assembly, software loading for product configuration, testing, packaging, shipment, and after-sales support. Handling multiple vendors for different services can be time-consuming and expensive. Hence, finding the right box-build assembly manufacturer is crucial for a successful product launch.

Building all the major components of your electronic product on a single shop floor can be highly beneficial. Collaborating with a box-build CM will improve data coordination, hardware compatibility, and system integration. But the capabilities of the service providers vary. It is important to evaluate their expertise, processes followed, the pricing offered, and delivery timelines before signing the contract. Based on the services required, the online quote calculator can assist you in choosing the best CM for your box building.

With the growing demands for miniaturization electronics, packaging of flex PCBs and HDI (High density interconnect) PCBs in compact enclosures largely depends on the efficiency of your CM. The complexity of the box-build assembly can be simple or advanced based on the end product. Fitting a single PCB in a chassis with no additional interfaces can be quite easy. But accommodating multiple PCBs with external connections to display units or other subassemblies may require additional assembly steps. In such situations, an experienced CM can foresee the possible obstacles and suggest preventive actions.

Prerequisites for box build assembly:

To start with a box-build assembly, you have to share certain important design details with your CM. Involving them from the early design stage can be beneficial as they can start working parallelly on their setup readiness. We are listing below the key requirements for a box-build assembly.

• Product dimension along with its weight
• Bill of Materials (BoM)
• Product 3D model using CAD tools
• Test cases like basic electrical safety testing
• Golden unit for reference
• Packaging and shipment guidelines
• Other design documents like schematics, wire list, and assembly drawings if required

In a box-build assembly, along with the electrical details of PCBs, it is necessary to share the mechanical specifications of subassemblies, cable drawings, connector interface diagrams, etc. A clear understanding of product dimensions is crucial as it impacts the box handling, storage, and delivery requirements. A multi-hierarchical PCB bill of material (BoM) includes both electrical and mechanical lists of components for the complete box assembly. It is necessary to perform top-level system testing before shipping the product to the customers. CM will ask for test procedure documents in such cases. Providing a sample unit for reference can result in a safe box building.

Process of box build assembly:

A box-build assembly consists of PCB assembly, cable construction, custom enclosures, heatsinks or fan assembly for heat dissipation, batteries for power backup, etc. The process starts with the system integration of tested PCBAs with associated circuitry. Verified cables are connected between PCBAs and user interfaces. The mechanical structure is assembled with connectors and brackets as per the design.

A basic visual inspection is conducted to ensure the correct and complete assembly of the box. Memory devices are programmed with setup configurations to boot up the system. Further testing of the overall system is performed as the test documents instruct. Reports are archived and correct labeling of the system is completed. The ready-to-ship products are stored as per the packaging instructions before deployment. The boxes are tracked till delivery to the customer and feedback is obtained.

Advantages of hiring a box-build assembly manufacturer:

There are several benefits associated with a box-build assembly provider. The system integration issues, and debug time can reduce significantly as the whole box is assembled and tested in one single place. Other merits are as follows:

• Product customization can be done easily along with quality control.
• Reduced production costs as the components are procured at competitive prices in bulk. Also, eliminating multiple vendor interactions saves time.
• A robust supply chain ensures a seamless assembly line with minimized downtime. This further improves the production yield.

How to choose the right box-build assembly provider?

As we know the merits of hiring a box-build CM, it is important now to identify the right service provider. Below are the checkpoints to choosing the best box-build assembly manufacturer.

• The experience of the CM should match the product type you are building. Handling the complexities of the latest technologies is crucial and needs expertise.
• As box building requires complete knowledge of system integration, the CM should be capable of assembling PCBs, cables, and mechanical enclosures. Adapting to the changes is key in the box-build assembly.
• Electronic products have to be compliant with various industry standards to assure user safety. This requires your CM to be ISO 9001 certified. Other industry-specific certifications for medical electronics and IATF 16949 for Automotives are also required based on the end product.
• Evaluate the engineering resources of your CM before signing the contract. Component sourcing, design assistance, and testing support should meet your product requirements. You need to have a dedicated support team and a point of contact for all your queries. The CM should have enough resources to handle your build load effectively.
• Identify the documentation process followed for tracking and issue resolution during the box build assembly process. This is important for quality analysis of the processes followed.
• The CM should have the latest equipment in the assembly line. All the machines should be calibrated and well-maintained. Based on the product complexity, your CM should be flexible to upgrade the assembly line to meet the delivery requirements.

Conclusion:

Box-build assembly has become popular in the industrial, military, and aerospace sectors. It is commonly used in control panels of manufacturing units. A box-build assembly provider offers diverse services like sub-system assembly, cable assembly, component labeling, enclosure fabrication, firmware configuration, etc. Based on the size and complexity of your product, the above checklist can guide you in finding the right box-build CM.

TechnoTronix excels in providing tailor-made PCB box build assembly services with its fully integrated advanced technologies. In case if you have any questions, please feel free to contact us via email at sales@technotronix.us or fill out the form below to request a free quote now.