Box Build Assemblies: Key Steps and Considerations

box build assembliesBox builds are also known as systems integrations and have several differences compared to the PCB (printed circuit board) production process. The key distinctive features include an electromechanical assembly of sub-assembly components in a more complex system that requires the fabrication of an enclosure (hence the name “box build”), wire harnesses, cables and so on.

The ranges and scales differ depending on application, industry and other factors. It can be a fully integrated system with pneumatic and mechanical components integrated with PCB parts, a small cabinet with PCB’s and wires, or anything in between.


The Box Build Assembly Process Includes the Following Steps

* System Level Design

* Sub-Level Product Assembly

* Product Assembly and Testing

* Software and Product Configuration

* Warehousing and Order Management

* Post-Sale Service and Repair


Important Considerations Regarding Box Build Assemblies

There are several things to keep in mind when planning a box build assembly.

Dimensions. This is one of the first questions your box build manufacturing company will inquire about. The size and weight of the unit should be determined in advance, as it will influence shipping, handling, storage and its subsequent installation in your destination facility.

BOM. Short for “Bill of Materials”, this is an important requirement for your electronic manufacturing company. It gives them a list of key components and materials which is an outline of the design itself (in rough strokes) as well as a general rough estimate of expected costs. Try to give as much detail as possible right from the start. Maybe not all the way down to nuts, bolts and washers, although sometimes clients will do that as well, which does help expedite processes.

Assembly Plan. The more accurate your plan is, the faster the box build assembly process will go. 3D CAD models are an asset in this case, and most electronic systems manufacturers will have software packages that allow them to take in and process digital CAD files, converting them directly into build instructions.

Sample Model. If you have a simple built model of the unit you require, it can provide key information about the plan. While not absolutely necessary strictly speaking, it is an asset and either it or the 3D model should be provided if you’d like to save time and costs on the provider creating the drawings for you.

There are other things to consider of course, but this list outlines the more important aspects pertaining to most box build assemblies.

Feel free to contact us at Star Engineering for more information on the topic.