The Role of Precision in PCB Manufacturing and Box Build Solutions

A box build assembly, which organizes the components of a PCB, serves as a protective enclosure for the electronic components within a device, shielding the PCB from external contamination, which can come from dust, moisture, or damage to the device. Box builds are typically recommended to ensure an electronic device’s safety, functionality, and durability. Still, there are best practices that can make for a more efficient and effective box build. Custom enclosures can be efficiently designed to enhance the aesthetic appeal of the design and the protection provided by the box build, and therefore, precision in box builds is paramount.Printed circuit board with electrical components lying on construction drawings.

What is Included in a Box Build?

A box build can also be referred to as a “systems integration” and will include all the assembly work involved, not simply the production of the PCB. A box build has been compared to a layered cake, where the success of each step in the sequence determines the project’s overall success. First, the PCBs, device cables, and wire harnesses will be built and tested. Then, the assembly will begin from the bottom, working through each level. This includes bolting parts together, seating and connecting boards, and connecting the wire harnesses. As each layer is worked on, manufacturing and workman specifications will be incorporated and inspected. This is crucial throughout the assembly, as certain layers won’t be accessible as the build continues. After all the layers are completed, a final inspection and test will take place.

Each box build is unique, and the full steps depend on the overall function of the completed product. However, there is a typical list of services that every box build will incorporate, including:

  • System level assembly
  • Product assembly
  • Sub-level product assembly
  • Packaging
  • Labeling
  • Testing
  • Software Installation
  • Product Configuration
  • Warehousing
  • Order Fulfillment
  • After-market service
  • Repair

A quality ECM will follow the box build through, from assembly and testing to the packing and delivery and throughout the product’s lifecycle.

Box Build Square

What is Needed from the Client for Precision in a Box Build Project?

To have a successful box build, the client and electronic contract manufacturer need to work together to ensure that all the information necessary is documented before the build begins. Some of the essential information required from the client includes:

  • Bill of Materials

The bill of materials (BOM) is the list of components involved in the assembly. The BOM provided to the ECM by the client should include part numbers, manufacturer names, quantity needed, reference numbers, item description, sourcing information, and any other specifics for the components included.

  • Design Files

3D CAD files are the best way to provide the assembly design information to the ECM. These files will contain all the necessary information for the completed device. The client should include an electrical schematic, wire lists, and even an example unit. However, a quality ECM can take a CAD model and adapt it into a working product.

  • Test Plan

One of the things a client can provide is detailed test cases on how the product will need to be tested before the final product can be accepted. Some of the tests a client may want are programming tests, functional testing, visual inspections, 3D automated inspections, factory acceptance testing, and more. The more comprehensive the test plan provided, the better the result will be from the ECM.

Finding the Ideal Electronic Contract Manufacturer for Precision in Box Build Solutions

The first step is to look for an electronic contract manufacturer who offers design assistance. Design assistance, including a DFM analysis, from on-site engineers is essential when it comes to box builds. You should be working with the engineers throughout the design process. You will need to provide the Gerber files, the CAD, and the BOM, but you will need to be more thorough with a box build than a simple PCB. What works in a CAD file for a PCB doesn’t always work for a box build. Design assistance from on-site engineers can direct you to what you will need for the best product. The engineering team should analyze the CAD file, Gerber files, and BOM to ensure that everything can be manufactured successfully. They will likely need even more information from you during the design process, such as dimensions and circuit diagrams. In addition, the ECM you partner with needs to have the knowledge, experience, and technical capabilities to handle the box build you need.

Not every ECM can handle a complex box build. When you look to outsource your box build, look for a company that has dealt with projects similar to the one you are bringing. Prototyping is vital in box builds; this is where a turnkey ECM with on-site engineers is crucial. Some ECMs don’t – or can’t – offer prototyping to the level that you need, but with a box build, you need this stage to see both the size and functionality of the product. An ECM with an on-site engineering team is critical to a prototyping and testing method that will ensure your project meets all the standards and requirements necessary before a full production run. This prototyping should also include a PFMEA (Performance Failure Mode Effects Analysis) to pass the build through to the production phase.

A high-quality electronic contract manufacturer will be able to design and build a custom enclosure for your box build assembly. When looking for an electronic contract manufacturer to partner with, it is essential to look for a domestic, turnkey facility that understands the importance of precision in box build assemblies and best practices for the most efficient builds. Whether you are working with a prototype for a new design or manufacturing a legacy product, including best practices for box build assembly can make sure your device is protected from the elements to function at the highest level.

Partner with Levison Enterprises

For precision-driven box build solutions that prioritize efficiency and effectiveness, partner with Levison Enterprises. With a commitment to meticulous attention to detail and comprehensive collaboration, we ensure seamless integration from design to delivery. Contact us today to initiate your next box build project and experience excellence in electronic manufacturing.

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