Full PCB Box Build

XDF system integration Services provide one-stop Box Build assembly which
include Product Assembly, Cable Assembly, System Level Assembly and various
other testings for effective use, Only accept less than 10K pcs order for now.

PCBA Box Build Assembly Services

Box build assembly is a full process service from PCB manufacturing, parts procurement, PCB SMT, assembly, and testing.

Box build manufacturing Service

XDF provides box build manufacturing service involving industrial controllers, consumer electronics, Internet of Things (IoT) modules, electronic and electrical equipment, etc. Box build is to assemble and produce the PCBA. It is boxed with cables and motion motors, then package to form a complete set of products and deliver to the terminal.

As an important part of EMS electronics manufacturing, the box build has many manual processes and requires strong process control and quality control capabilities. During the box build process, management methods such as related SOP operation standards, station self-inspection, QC full inspection, QA spot sampling inspection, and pre-shipment OBA sampling inspection must be strictly implemented.

 At the same time, a barcode management system is adopted to effectively trace and register to distinguish between good and bad products to achieve the desired goal of assembly straight-through rate and customer quality sampling pass rate.

Box build assembly is an important aspect of electronic production. Most electronic devices contain box build assembly.  The use of box build assembly can never be underestimated. In this article, we will be discussing what you need to know about PCB box build assembly.

What is a Box Build Assembly?

A box build, which is also known as systems integration, contains other assembly work in an electromechanical assembly.  It includes installation of sub-assemblies, enclosure fabrication, and the installation and routing of wire harnesses. Box build assembly isn’t all about the production of PCB, it goes beyond that.

Box build assembly involves the assembling of different circuit boards connected via different wiring and with some cables. There are several sub-assemblies and other electronic components you install in the assembly. Box build assembly refers to all assembly processes involved in electronics production and design chains.

Key Considerations in Box Build Assemblies

To get a good box build assembly, there are certain factors you must put into consideration. It is important you provide your service provider with these pieces of information.

3D CAD model: A 3D CAD model should be provided to have better visuals of the final product. There are several CAD packages you can choose from. These packages provide free drawing viewers and they allow you to transform your drawings into build instructions. It is very important to create a layout drawing having all the important components. The tools in 3D CAD can also help you reduce the process it takes to complete box build.

Product dimensions: The product dimensions should be specified. This includes the weight and size of the assembly. This information helps you to make decisions on several factors such as delivery, storage, handling, and other processes. Your EMS will also make decisions on how to handle the units all through the box build assembly process.

Bill of materials: Your Electronic Manufacturing Services (EMS) needs to be aware of this vital piece of information. It is regarded as one of the integral aspects of the box build assembly process. With the bill of materials, the EMS will have knowledge about the key materials and components you need to source out.

Each item on this bill has a particular associated cost, purpose, and procurement process. This bill contains information as regards the manufacturing name, part description, package type, reference designator, quantity, item number, and more. A detailed bill of materials will make work less stressful for the EMS provider.

Sample prototype: To plan a safe box build, you need a completed product assembly, particularly when other information sources aren’t available. A rough prototype can be used to produce several equivalent assemblies. With just minimal documentation, an experienced electromechanical assembly engineer can make a copy of a complete box build.

Testing: It is important for a customer to identify the kind of tests an EMS provider should carry out during box build assembly. Some testing involves factory acceptance testing, specific functional tests, and visual inspection.

Safety is a key factor to consider. An experienced EMS goes for the best test that can help you to maximize production time during the box build assembly process. It will also offer a safe and reliable electromechanical assembly.

Packaging and shipping details: You need to provide vital information to the electronics manufacturer. This information is helpful to the EMS as it helps to decide how the units will be handled. It is important you define the packaging and shipping of the complete box build assembly before the manufacturing process begins.

Benefits of Good Box Build Assembly Services

Box build assembly services offer several benefits for users. This assembly can include items such as pneumatic devices and further electronics to the printed circuit boards.

Reduction in production costs: Electronic manufacturing services can pay for fewer wires, connectors, and tie wraps that you might purchase in small lots. A good build assembly service ensures that its employees understand the testing and installation of different build boxes.

Experience helps to improve work quality and productivity. One of the benefits you enjoy when you employ the services of EMS is that they can switch between models easily.

Quality: Good PCB box build assembly services ensure they do the right job. They do their job with quality in mind. Working with a box build assembly service that ensures good systems integration by carrying out some tests is important for higher assembly processes.

Supply chain simplificationThis is what competent box build assembly services do. These services provide expertise. They can tell you what to do about streamlining your design. They will reduce the complexity of your overall supply chain since they are responsible for creating or purchasing cables, circuit boards, and chassis.

The Process of Box Build Assembly

The box build assembly process involves creating a device. The creation of this device includes the PCB, wires and cables installation, the enclosure, etc. The build box ranges in size. The assembly process of a box build includes the following;

Integration of system: The build box assembly process involves product assembly, packaging, and system level assembly. These processes involve other repetitive tasks such as testing, loading of software, and product assembly.

The post-assembly processes involve activities like depot repair, order fulfillment, aftermarket service, tracking, and warehousing. System integration begins with specifications, models, and a list of materials. It ends with a well-packaged finished product for the end-user.

Specifications and requirements: There are certain materials and processes that determine box build. Before manufacturing takes place, there is always a bill of materials. If the necessary supplies aren’t available, they should be made available before the manufacturing begins. The PCB assembler can source smaller items like screws, bolts, and washers while the owner can source major items such as the PCB.

The bill of material is very important as it helps to project the supply requirements. A thorough study of this bill before assembly can help to prevent delays as a result of shortages. A 3D CAD model can help the assembly process. The assembly utilizes the 3D CAD model to create the process flow. Tagged parts are some of the parts of the CAD model. You supply these parts to the assembly line.

The size and weight of the product are available in the specifications, but it is important to deliver the information to the assembler. The assembler will be able to make further preparation for storage, handling, and shipping. The specifications of the product also determine how it is packaged.

Testing: This is a vital aspect of the box build assembly process.  Product testing involves testing for electrical safety and random testing.  This has to be done between during the manufacturing of the product and after. Some products don’t need testing, but it is important to inspect the individual items.

Testing the software is a different activity with several levels. You should test the software on the component alone.  You might have to test the entire assembled product to know if it suits the requirements of the system. Detecting any software problems before the whole assembly is important.

Assembly outsourcing: Box build assembly manufacturers will source out box build to the assembler. These manufacturers depend on the professionalism of these assemblers to ensure the products are made to meet the right specifications and standards.

This also helps to build manufacturing plants and employ people for the job. It is very important you make your requests known to the assembler. The assembler will be able to understand the requirements and products important for smooth production.

Applications of PCB Box Build

PCB box build is used in several applications such as;

Aerospace and military sector: This box build is utilized in the production of core electronics used in the aerospace and military sector. These sectors keep demanding reliable PCB box build.

Industrial sector:  The industrial sector also demands reliable and high-end PCB build boxes. Heavy industries need this box for their machines. This box offers these machines high performance and quality control.

The computer system: The box build assembly is commonly used in the computer industry. The computer system needs a high-end build box for some parts of the computer. All computers contain a PCB build box in some of their parts.

Frequently Asked Questions

What do box build assembly services offer? Box build assembly services offer wiring harnesses, electro-mechanical assemblies, custom packaging, functional testing, and environmental testing, sub-level product assembly, software installation, cable assemblies, and low-cost component sourcing.

What are the types of box build assembly? There are two major types of box build assemblies. They are simple and complex box build assemblies. Both box build assemblies require certain processes to achieve them.  


Box build assemblies are commonly utilized in industries such as military, telecommunications, satellite, aerospace, and medical. These assemblies offer a wide range of benefits. They serve as the core of most electronic devices and as such, the demand for them keeps increasing.

The scales and ranges of box build assembly vary based on industry, applications, and other key factors. This assembly can be a system with mechanical and pneumatic components incorporated with PCB parts.

Advantages of our PCBA electronic product box build

  1. 95% skilled workers, one person for one post.The workers are trained by strict team leaders responsible for on-site prevention and correction; employee skills are guaranteed.
  1. Team leaders patrol the production line throughout the whole process, responsible fortimely statistical analysis of defective items in the assembly process, improvement, and promotion of quality.
  1. Implement strict SOP operating standards, including content items such as operating methods, IPC quality standards, tooling and equipment, and statistical analysis.
  1. On-site QC 100% full inspection, QA conducts random inspections in accordance with AQL standards, and timely discovers and controls defectiveitems in the process.
  1. Before the product is packaged and shipped, the quality department conducts OBA unpacking inspection.
  1. The production line is equipped with complete operating equipment, such as electric screw drivers, magnifyingequipment, air-gap torsion meter, dispensers, E-test fixture, and various auxiliary inspection equipment.
  1. Strict material area division in the assembly line to prevent mixing of materials and boards.
  1. Have experiencein box build sophisticated and complex products.

XDF provides one-stop PCBA electronic manufacturing services with rich experience in box build. Professional electronic engineers can follow up on technical problems in the box build process on-site and help customers remotely joint debugging to solve problems in the upper computer software, test system, assembly process, etc.

The world of electronics is very vast. There are countless products in the world that contains PCBs inside. Although we know that PCBs are the core of any electronic product but have we ever thought of how their enclosures were made ? Yes enclosure or simply we can say “box” is the mechanical compartment where PCBs reside. These boxes can be in different shapes and sizes. Variety of complexity of mechanical designs of enclosures can show how advanced the product is.

For example a simple enclosure/box that is rectangular shape, small in size, having small LCD display and 2 push button on front panel and one power socket and temperature sensor probe input connector on rear panel is a simple example of box assembly. There can be multiple or single PCBs fitted inside and a few wire cables inside for interconnectivity.

On the other side a complex enclosure is the one having complicated process of dismantling the assembly, having various kinds of wiring harness, special kinds of nuts and bolts like Allen key or star key bolts, having a proper guide book how to open the unit like in hp Synthesized signal generator disassembly, Anritsu or Shimadzu Spectrum analyzer dismantling and other kind of complicated machines disassembly having complicated PCBs mounted / fitted inside.

There are numerous gigantic electronic manufacturing companies means OEM like Hp, Dell, SamsungHuawei and others who have dedicated mechanical engineering teams who are expert in mechanical enclosure designing, fitting sub-assemblies, integration and testing of a final product before it is forwarded to quality control checks and then floating product in  market for sell.

Typical Box Build Assembly Services:

In every electronic product or equipment you would find the box assembly that provides the solid casing, safety and good aesthetic look to the end product. The CEM providing this service usually works on following domain

1. 3D CAD Model Design

There are numerous software available for mechanical design of 2D and 3D modeling. Normally Solid Works and PTC CREO are used by many design engineers and CEM companies hire those mechanical engineering experts having full command on these CAD software


There are too many things like clearances, dimensions, pitch, inner and outer diameter and other to consider in order to make a perfect 3D model that will be used in fabrication or box build assembly.  

The design and validation engineers will make sure that 3D models must comply with the standards being set by QC engineers and that when assemblies and sub-assemblies are integrated with each other, they will not become loose, tight and disoriented.

2. Material of Enclosure Selection:

There are various types of materials available for PCB enclosure like ABS plastics, plastic, acrylic plastic, sheet metal and wood. Special dies and molds are made for plastic body making however for sheet metals and acrylic plastics, simple laser cutting can be used.

3. System Level Integration:

The most important service of the box building assembly company is the combination and interfacing of various sub-level assemblies like power supply board, mother board PCB prototype assembly , heat sinks, fans, display panels PCBs, memory card slots, Input/output interface circuits, electromechanical assemblies and many other assemblies that may be the part of overall product.

 Interfacing requires many things like ribbon cables, multiple or single stranded electrical wire, RF coaxial connectors, wire grips, headers, BNC connectors, lugs, earth or ground connections to metal body, apply thermal paste to heat sinks components, use tie wraps

4. Product Assembly:

As soon as the sub-assemblies are assembled, now is the time to pack them in final enclosure by riveting, screws hole drilling, tightening nuts and bolts, using washers and mechanical locks on sheet metal plates. The sheet metal plates are done Insulation, polishing,  blasting, cutting, welding, straightening and then finishing and then these plates are combined with each other to form a complete box.

 After this the subassemblies are placed inside and final screws are tightened to properly secure the enclosure. Many renowned CEMs use too many screws to fasten the top, bottom, side metal sheet covers to make strong and robust body of product as shown in previous figures of HP spectrum analyzer.

5. Programming /Configuring:

Now that the complete product is assembled and properly enclosed, it is time now to do initial factory programming or configurations. Most of the high end electronic equipment require programming like date and time setting, manufacturer codes, system file configuration and BIOS update. 

This is all done by normally available external LCD screen in most of the products and the program is fed in the memory ROM once and for all. After this OTP (One Time Programmable) chip is ready to do self test whenever the product is turned ON. This self test allows the product to scan its subassemblies for any malfunctions that may be possible and if found OK it goes ahead otherwise it shows error messages. 

The error message details are usually defined by OEM or ODM in their catalog/user manual for users. The memory ICs like RAMs and other re-programmable SRAM can be used by user to feed their customizable programs to make product function accordingly. Note that these functionalities are only applicable to high end advance electronic equipment or instruments like the one shown in figure below and not for casual/usual electronic products.

6. Labeling and Logo Mark:

Another important task is to emboss or print logo and stamp label on the body of the product as desired. The logo can be a high voltage danger logo with skull or electric arc showing, labeling the power outlets, keypads, display screen readings like volt, ohm, ampere, signal levels, frequency, counter values, etc. The significant label is indeed the logo of the company that shows the intellectual property rights of that particular ODM

7. Testing:

The box build assembly manufacturers must also do final testing to check the functionalities of the product after all above prior steps are done. This test can be anything from (talking about the Function Generator) power on/off test, signal output waveforms analysis, impedance matching test, keypad input testing, frequency, amplitude, DC offset and phase test etc etc.

8. Warehousing:

Next step is to properly store the product in a well maintained warehouse where temperature and humidity is controlled. Proper cleanliness of warehouse should be assured.

9. Order from Client:

The next step will be to fulfill the order that is raised from client promptly. Product must be delivered with complete warranty card, user manual, service manual, assembly and disassembly guideline to user, Comprehensive parts list detailing the minute to largest components either mechanical, electrical or electromechanical that is used in the product. 

Some product service manuals have huge details of  electronic components used and even the details of screw and its size, dimension, orientation and placement. The parts list is a tricky thing and every component/part must be given unique identity so it can be traced by trained technicians when dismantling the product when needed. 

Usually it is recommended that these sophisticated electronic equipment must not be dismantled by common users except for the well trained professional technicians or by service support team of ODM/OEM/EMS.

10. After Sales Services and Repairs:

As the product is now sold to user, the box building assembly company that is usually the EMS or CEM (Contract Electronics Manufacturer) must also provide value added services like repairs, calibration, periodic maintenance under warranty.


Mostly the CEMs are working on the product from A to Z. Like starting from design files either the design files of PCB circuits or 3D design files of box building assembly and completing till the complete product is finished and delivered to user. Even after sales, the CEM provides services as mentioned in paragraph 10 above. Hence it is recommended to choose a CEM that can provide professional services in both electronics and mechanical side considering extensive expertise in above mentioned ten services.

Precautions of PCBA box build assembled

First – Pay attention to electrostatic protection

  1. Production workers need to wear electrostatic hand rings.
  2. Soldering iron, air gun, workbench to do grounding treatment.

Second – Battery speaker welding, placement of the substrate, and the whole machine assembly test precautions

  1. PCBA substrates need to be placed neatly, and bare boards cannot be stacked directly. If you want to stack them, you need to pack them instatic bags.
  2. PCBA needs to pay attention to the solder joints when welding the speakers and batteries, do not usetoo much tin, as it can cause a short circuit or fall off to the surrounding components.
  1. PCBA cannot work with electricity during the assembly process. For example, Supposed the battery should be welded at the end. However, it is then communicated thatthe battery needs to be soldered first during the production process due to other requirements. In that case, the reset button should be pressed immediately after the battery is soldered.
  1. Battery welding attention to positive and negative polarity needs to be correct.
  2. After the screen and lens module are connected, it should be checked for proper connectionand other abnormalities, such as skewed FPC reinforcement. Fix connections if needed.
  1. Test the power supply. Thevoltage should be 5V.
  2. Power on the test measurethe current. If the current exceeds the normal range, disconnect the power immediately.


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