/Integration from PCBA to Finished Product/
Box Build Assembly
Box Build Assembly is the complete integration process that transforms PCBA into fully functional, tested, packaged, and shipment-ready electronic products.
At PCBSAIL, we deliver end-to-end Box Build Assembly solutions. We can combine precision electro-mechanical integration, cable harness fabrication, firmware loading, system-level testing, and retail-ready pack-out under a single accountable workflow.
Box Build Assembly Supplier.
As a China-based PCB and PCBA manufacturer, we extend our expertise beyond board-level assembly to provide finished products.
Our Box Build Assembly capacity is structured to support prototype, low-volume, and high-volume production with stable quality and digital traceability.
Our facility can integrate electro-mechanical assembly cells, harness production lines, firmware programming stations, and system-level testing under one MES-controlled workflow.
Our integrated manufacturing system operates under internationally recognized quality frameworks, such as IATF 16949 and ISO 13485.
It can ensure audit-ready performance for automotive, medical, industrial, and high-reliability electronics programs.
Box Build Assembly Capabilities
We offered vertically integrated manufacturing, covering PCB fabrication, PCBA, electro-mechanical assembly, firmware programming, system-level validation, and logistics.
Mechanical Integration
- Enclosure size up to 600 × 600 × 250 mm
- Rack-mount, desktop, and IP54–IP65 housings
- Calibrated digital torque drivers (±5% accuracy)
- Torque logging tied to serial numbers
- EMI shielding installation
- Thermal interface material application
- Conformal coating and curing
- Gap and tolerance verification
Cable Harness Fabrication
- Wire range: AWG 28–8
- Cut, strip, crimp, and termination
- IPC/WHMA-A-620 workmanship standard
- UL 1007 / 2464 compliant wires
- Barcode and color-coded labeling
- Continuity and hi-pot testing
- Harness routing and strain relief installation
Firmware Loading & Configuration
- JTAG programming
- SWD programming
- USB-based firmware loading
- Parameter configuration
- Calibration data writing
- Firmware revision capture per serial number
- Secure boot configuration
System-Level Testing
We perform 100% functional checks including:
- ICT (In-Circuit Test)
- FCT (Functional Circuit Test)
- Boundary-scan testing
- Hi-pot testing (up to 5 kV)
- Power-on validation
- Parametric verification
- Temperature cycling (optional)
- Vibration and humidity screening (optional)
Box Build Assembly Feature
At PCBSAIL, our vertically integrated model transforms PCBAs into fully tested, serialized, and packaged finished products—while reducing supply chain risk and improving overall product reliability.
Single-Source Manufacturing Accountability
Instead of coordinating multiple vendors for PCB assembly, mechanical integration, harness fabrication, firmware programming, testing, and packaging, Box Build Assembly consolidates everything under one controlled workflow.
- Eliminates cross-vendor miscommunication
- Prevents configuration mismatches
- Reduces scheduling conflicts
- Improves version control
- Provides one accountable manufacturing partner
A single-source model simplifies program management and lowers operational complexity.
Reduced Supply Chain Risk
Multi-vendor integration often creates traceability gaps, torque inconsistencies, firmware revision errors, and uncontrolled test coverage. Our unified manufacturing execution system (MES) ensures:
- Component-level traceability
- Firmware revision tracking
- Torque log capture per serial number
- ICT/FCT/hi-pot test documentation
- Controlled document management
Faster Time to Market
Integrated Box Build Assembly significantly shortens production cycles. Vertical integration typically reduces total lead time by 20–25%, accelerating product launches.
Reliability
System-level integration ensures mechanical, electrical, and firmware elements function together as a validated system.
Reliability Improvements Include:
- Controlled digital torque (±5% accuracy)
- Verified cable routing and strain relief
- EMI shielding installation
- Thermal interface management
- 100% functional and hi-pot testing
- Optional burn-in and environmental screening
This reduces field failure rates and warranty returns.
Full-System Validation
Unlike simple PCBA services, Box Build Assembly verifies performance at the complete product level.
Testing May Include:
- In-Circuit Test (ICT)
- Functional Circuit Test (FCT)
- Boundary scan
- Power-on verification
- Load simulation
- Hi-pot testing up to 5 kV
Every finished product is validated prior to shipment, minimizing post-delivery troubleshooting.
Why Us
At PCBSAIL, we combine PCB manufacturing, PCBA, electro-mechanical integration, firmware programming, system-level testing, and global fulfillment under one controlled manufacturing ecosystem.
Integration Capacity
We are not just a contract assembler. We are a PCB and PCBA manufacturer with in-house system integration capability.
- PCB Fabrication
- SMT & THT Assembly
- Cable Harness Production
- Enclosure Integration
- Firmware Programming
- ICT / FCT / Hi-Pot Testing
MES Traceability
Every finished enclosure ships with digital records tied to its serial number:
- Component Batch Traceability
- Firmware Revision Capture
- Digital Torque Logs (±5% Accuracy)
- ICT / FCT / Boundary-Scan Results
- Hi-Pot Testing Data
Mechanical Precision
Box Build Assembly is not only electrical—it is mechanical integrity. We Provide:
- Calibrated digital torque drivers (±5%)
- Torque value logging per fastener
- Gap and tolerance verification
- EMI shielding installation
- Thermal interface control
- IP54–IP65 enclosure support
- ANSI/ESD S20.20 compliant workstations
Test Coverage
Each finished product undergoes system-level validation:
- In-Circuit Test (ICT)
- Functional Circuit Test (FCT)
- Boundary scan testing
- Power-on verification
- Load simulation
Engineering-Driven Manufacturing
We support projects from early development through volume production:
- DFM Review
- DFT Planning
- Custom Test Fixture Development
- Assembly Sequence Optimization
- Reliability Risk Analysis
Production Capacity
We support:
- Prototype builds (1–200 units)
- Small-batch production
- High-volume production
Strong Supply Chain
Our long-term supplier network ensures:
- Stable material sourcing
- Dual sourcing strategies
- End-of-life (EOL) component monitoring
- Inventory management control
- Reduced procurement delays
Industries We Have Previously Served
With vertically integrated PCB fabrication, PCBA, harness manufacturing, enclosure integration, testing, and global fulfillment, we provide turnkey solutions for regulated and performance-critical markets. Below are the primary industries we have previously served through our Box Build Assembly programs.
Consumer products require cosmetic quality, retail packaging, and strict configuration management.
- Smart Appliances
- Wearable Device Modules
- Display-Driven Control Units
- Embedded Electronics Platforms
Automotive Electronics
We support Tier-1 and Tier-2 suppliers with system-level integration under quality frameworks aligned with the International Automotive Task Force.
- Electronic Control Units (ECUs)
- Battery Management Systems (BMS)
- Power Distribution Modules
- Charging Control Units
- In-Vehicle Communication Gateways
- Telematics Modules
Industrial Automation
Industrial systems require durable mechanical integration and stable long-term operation.
- PLC Control Units
- Industrial Iot Gateways
- Motor Controllers
- HMI Control Panels
- Power Management Systems
Medical Devices
For medical device manufacturers, we provide controlled and documented system integration.
- Diagnostic equipment
- Patient monitoring devices
- Portable analyzers
- Laboratory instruments
- Medical imaging sub-systems
Consumer Electronics
Consumer products require cosmetic quality, retail packaging, and strict configuration management.
- Smart Appliances
- Wearable Device Modules
- Display-Driven Control Units
- Embedded Electronics Platforms
Telecommunication
Telecom systems require consistent performance, EMI control, and reliability under continuous operation.
- Network Routers
- Communication Gateways
- RF Control Modules
- Data Acquisition Systems
- Edge Computing Hardware
Fast Quotation
Our professional sales and engineering teams provide fast PCB quotes and technical support. Simply send us your Gerber files, BOM, and assembly drawings, and we will respond promptly with a competitive solution.
- Gushu Tangxi Second Industrial Zone, Shenzhen
- +86 755 2335 0814
- +86 135 1078 8094
- sales@pcbasail.com
FAQ About Box Build Assembly FAQ
1. What is Box Build Assembly?
Box Build Assembly refers to the complete integration of an electronic product after PCB assembly. It includes:
- PCBA installation into enclosure
- Cable harness fabrication and routing
- Mechanical hardware assembly
- Firmware loading and configuration
- Functional and safety testing
- Labeling, serialization, and packaging
The final result is a fully assembled, tested, and shipment-ready product.
2. What is the difference between PCBA and Box Build Assembly?
PCBA (Printed Circuit Board Assembly) involves mounting and soldering components onto a PCB.
Box Build Assembly goes further by integrating the PCBA into a mechanical enclosure, adding wiring harnesses, loading firmware, performing system-level testing, and preparing the finished product for shipment.
In short:
PCBA = Board-level assembly
Box Build Assembly = Complete product integration
3. What Enclosure Sizes Can You Handle?
We support enclosure dimensions up to:
600 × 600 × 250 mm
We assemble:
- Rack-mount systems
- Desktop units
- Wall-mounted industrial devices
- IP54–IP65 rated enclosures
4. Do You Provide Cable Harness Fabrication In-House?
Yes. We manufacture harnesses internally to ensure quality and integration consistency.
Capabilities Include:
- Wire range: AWG 28–8
- Cut, strip, and crimp processing
- UL 1007 / 2464 compliant wiring
- Barcode and color-coded labeling
- Continuity testing
- Hi-pot testing
- IPC/WHMA-A-620 workmanship standard
5. What Testing Is Performed During Box Build Assembly?
We provide 100% functional verification before shipment.
Testing May Include:
- In-Circuit Test (ICT)
- Functional Circuit Test (FCT)
- Boundary-scan testing
- Power-on verification
- Load simulation
- Hi-pot testing up to 5 kV
- Ground continuity testing
Optional Reliability Testing:
- Burn-in (4–72 hours)
- Temperature cycling
- Vibration screening
All results are digitally recorded in our MES system.
6. What Is Your Standard Lead Time?
Typical lead times:
- NPI builds: 10–15 working days
- Low volume: 15–25 days
- Mass production: 30 days
Expedited options are available depending on component readiness and project complexity.
7. Can You Manage Component Sourcing?
Yes. We provide centralized procurement with:
- Approved supplier network
- Dual sourcing strategies
- End-of-life (EOL) monitoring
- Inventory buffer planning
- Supply chain risk mitigation
This reduces delays and pricing volatility.
8. How Do You Support New Product Introduction (NPI)?
For NPI programs, we provide:
- DFM (Design for Manufacturability) review
- DFT (Design for Test) planning
- Assembly sequence optimization
- Custom fixture development
- Pilot run builds
- Yield performance analysis
It ensures a smooth transition from prototype to mass production.
9. How Do You Protect ESD-Sensitive Components?
Our facility maintains:
- ANSI/ESD S20.20 compliant workstations
- Grounded assembly cells
- Continuous ESD monitoring
- Moisture Sensitive Device (MSD) control procedures
This protects sensitive electronics during full system integration.
10. How Do You Maintain High First-Pass Yield (FPY)?
We achieve 98–99% FPY in stable production through:
- Structured assembly work instructions
- Statistical Process Control (SPC) monitoring
- Digital torque verification
- Full functional testing
- Early engineering involvement
Continuous improvement programs maintain production stability.