Cutting-Edge Developments in Box Build and Cable Assemblies

Box builds and cable assemblies play an important role in the electronic manufacturing process. Once electronic components are designed and manufactured, they must be housed and integrated into an enclosure. This stage—known as the box build—brings together all components, including PCBs, cables, connectors, and other hardware, into a complete, functional unit.

A well-executed box build is essential to the overall performance and reliability of the final product. It should not be treated as an afterthought. Instead, this stage deserves careful attention, with a focus on both best practices and the latest technological advancements to ensure long-term success.

Design for Manufacturability is Becoming More Common

Design for Manufacturability (DFM) has always had value, but as it becomes more of a standard best practice, more developers and designers are realizing the positive impact DFM can have not only on the component itself, but the box build and cable assembly as well. During DFM analysis, optimized component placement, enclosure design, material selection, and manufacturing processes can all be considered from the start. Collaboration on the box build and cable assembly—starting as early as possible—helps ensure the use of best practices, the latest developments, and materials that are both advanced and readily available. It also supports easier assembly, as well as better access for testing and maintenance of the electronic components. Collaborating with the full team at the earliest stages is one of the best ways to get the best results for box builds and cable assemblies. All potential issues can be identified, avoiding costly delays and ensuring the best results.

Advanced Material Options

Custom enclosures are more common now, as a custom box build allows the design and development team to work with the ECM to design a build that will not only be effective, but will reflect the best design choice. Choosing the materials for a box build and cable assembly system is a balancing act between the best materials with what is readily available from vetted suppliers. Stainless steel sheet metal remains the most popular choice due to its availability, ease of machining, and low cost. However, advances in materials have led some developers and manufacturers to explore alternatives such as injection-molded plastic, copper, or thermoplastics. In addition to the materials of the build itself, there have been great advances in coatings for box builds that prolong the life of the device. When considering which materials are best, think of the operating environment, including temperature, humidity, and contamination risks. If an electronic component will be exposed to water, chemicals, extreme temperature, or electromagnetic interference, the materials will need to be able to withstand the conditions and protect the electronic components.

Modular Designs

The primary purpose of a modular design is to break down the electronic assembly into smaller subassemblies, or modules. Rather than one cluttered or complex box build or cable assembly, a smaller module is far more manageable. While the reduced assembly process of the smaller module is obviously a benefit, another is the simplified troubleshooting and repair. If adjustments need to be made to the electronic components, each module can be dealt with individually, rather than needing to remove the entire electronic system. As needs evolve and technology advances, having a box build built with a modular design makes adapting far easier.

Quick-Connect Systems

Quick-connect systems are designed for a better user experience. A user-centric box build will make the end product easy to operate, maintain, and service. The design team can focus on the user experience and how quickly a user will be able to connect to their existing products. While customization can work very well, having standardized components that will integrate smoothly across different systems and platforms is also important.

Testing is Advancing, Providing Better Feedback and Better Results

The more testing that can be done throughout the process, the better the ultimate results. Tests will identify any potential issues and ensure the reliability of the enclosure. These tests include X-ray inspection, circuit testing, probe testing, dielectric testing, functional testing, environmental testing, compression testing, and shock testing. The more rigorous the testing protocol, particularly early in the design process, the more effective the final box build design will be.

Planning for the Future

As box build and cable assemblies continue to advance, one of the best things that ECMs and designers can do is to keep the box build and cable assembly designs flexible. Creating expandable systems that will be able to accommodate additional components or functions will ensure that an electronic device can be “future-proofed”. A device contained within a cutting-edge box build can be easily upgraded and adjusted to support a range of requirements that may be necessary during the product lifecycle, keeping the product in use and protecting the investment.

Having a quality box build that incorporates advancements in technology with ease of use can help quickly deliver high-quality electronic products to market. By using the best materials, most advanced machining, and focusing on getting a DFM early in the process, your box build enclosures will protect the electronic components and allow for the best possible operation. When you are outsourcing your PCB assembly and box builds, look for an ECM who is committed to continuous improvement and best practices. A high-quality ECM will be committed to delivering a customized solution that meets all of your needs.

The Levison Difference

As electronic manufacturing continues to evolve, the role of box builds and cable assemblies has never been more important. From early-stage collaboration and DFM strategies to material innovations, modularity, and advanced testing, each element contributes to building reliable, efficient, and future-ready electronic systems. Staying ahead means embracing these developments—not only to meet current design and production needs, but to ensure adaptability for what’s next. Whether you’re designing for performance, durability, or scalability, partnering with Levison Enterprises will set your product up for success from the inside out. Contact us today for a quote.

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