Top 5 Things to Consider for Box Build Assembly Process

By | Date posted: | Last updated: April 15, 2021
Box Build Assembly Process

A box build or what is also known as systems integration is essentially an electromechanical assembly process. It includes all the assembly work involved in electromechanical assembly except for the production of PCBs. While the box build assembly process is specific to a project, it largely includes:

  • Enclosure fabrication
  • Installation
  • Routing of cable harness
  • Installation of sub-assemblies
  • Installation of components

Simply explained a box build can be imagined as a large cabinet of wires and that is how it perhaps gets its name too. It actually not just includes system, product and sub-product assembly as also the process of packaging, labelling, testing, warehousing, aftersales and more. Should you want to opt for a box build assembly process, there are a few things that you simply cannot ignore.

Here is a handy list for a box build assembly process:

Bill of Materials

This is an important requirement not just for box build but for any electronic manufacturing services provider. The bill of materials will ensure that all the key components are listed. Ideally, the Bill of Materials should list not just the key components but also small essential elements such as:

  • Wires
  • Nuts and bolts
  • Washers
  • Heat Shrinks and more

Not only does providing for them ensure that there is no increase in cost later, importantly it will ensure that no production delays occur on account of these essentials not being available.

It is also important to remember that the Bill of Materials should be comprehensive and should include details such as:

  • Item Number
  • Part Description
  • Quantity
  • Name of manufacturer and more

The more comprehensive it is, the sure you are that there are no communication gaps and that the provider can plan the entire process efficiently. In case certain parts aren’t available, with a detailed description, alternate parts can also be sourced easily.

3D CAD model

Providing a 3D CAD model is a big benefit as there is no better way to visualize the end product. In fact, with a large number of CAD packages available, there are free drawing viewers that are accessible easily. However, it is essential to have a detailed layout drawing with key components fully labelled. The provider can often have their own CAD packages that help convert drawings to instructions. It is important to have the layout drawing show details such as routing of cables etc. The provider can then take the decision on the best build method.

Sample Unit

Especially in cases where there are unfinished drawings, the importance of a sample unit cannot be overstated. The unit can be a key source of data. In fact, a sample prototype can help the provider to replicate the box build in the absence of documentation.


A clear understanding of the dimensions is required not just so that shipping but also handling and storage can be efficiently planned. In fact, discussing how the final box build PCB assembly will be packaged and shipped, is an important conversation to have, so that the provider can take the necessary decisions early.


 An aspect that cannot be ignored when it comes to electrical systems is testing. In fact, there can be a wide range of testing that you could consider – from functional testing to factory acceptance testing, visual inspection and more. It is imperative that you discuss this aspect with the provider right at the beginning. An experienced provider can guide you on the type of testing required so that safety isn’t compromised at any level.

 Whether you require a fairly straight forward box build assembly or a more complex one, a clear understanding of the above will ensure that you get the best results and that everyone knows what is required so there are no chances of anything being overlooked. In fact, if there is one thing that is imperative to make the outsourcing job successful, it is thorough communication with the assembler, so that they completely understand and deliver your exact requirements.

Additionally, Choosing a professional provider who uses lean manufacturing techniques will ensure that the assembly is efficient and effective. It is the experience and expertise of the provider that will ensure that the assembly is made to exact specifications. Additionally, you will stand to reap the advantage of speed and cost besides having to deal with few suppliers.

When executed correctly, a box build assembly can deliver on the parameters of:

  • Quality
  • Reliability
  • Productivity
  • Manufacturability

With a professional provider supporting a wide range of industries, it can deliver end-to-end solutions. So much so that you could have them ship the final products to the end-user directly as well.

Technotronix Inc is a California based PCB Manufacturing and PCB Assembly Company offering Box Build PCB, PCB Prototyping, PCB Fabrication, Turn Key PCB Assembly, PCB Material Management, SMT PCB Assembly, Flexible PCB Production and many more Services as per custom requirements and specification.

In case if you have any questions, Please feel free to contact us via email at or call us at 714/630-9200.

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