Box Build Assembly: Board Fab to System Integration

A Superior Box Build to Precisely
House Your Device’s Electronics

New needs, challenges, and opportunities present daily, and the solutions require innovative electronic designs. These designs are powered by advanced software and user applications and supported by the latest hardware design. However, another critical element of this product development cycle remains overlooked—the enclosure or box build containing these new electronics.

While it may seem like a box build assembly is simple, quite the opposite is true. A box-build assembly must meet the design specifications and applicable safety requirements simultaneously. Additionally, box-build designs house all printed circuit board assemblies, user interfaces, and the interconnecting wire harness assembly, offering protection and mechanical stability to the system. Where other vendors can provide one of these services, VSE furnishes a singular, turn-key process that encapsulates all device manufacturing components. This capability uniquely positions VSE to understand customer needs and requirements to provide superior PCB box-build assembly services.

What’s in a PCB Box Build
PCBA	Wire Harness / Cable Assembly	Enclosure
Includes the fabrication (bare board) and component assembly Fabrication stackup must consider electrical, thermal, and mechanical characteristics for optimal performance Assembly must reliably bond components while minimizing thermal wear	Creation of custom cables for taxing applications and environments Routing of the connections in 3D space to optimize service life (i.e., bend radii versus cable thickness)	The MCAD-ECAD integration of the system assembly within a protective enclosure Minimizes shock/vibration and debris/moisture ingress Has to incorporate active/passing cooling

From PCB Manufacturing to Box-Build Assembly—All In One Location

Many vendors can provide box-building services, but very few have the expertise to build and test the electronics that go into the boxes. A segmented manufacturing job requires work with multiple vendors to assemble your device’s pieces, which can increase the risk of miscommunication, errors, and delays. With VSE, all of the significant components of an electronic device—the PCB, the wire harness assembly, and the box—come together under one roof, offering several benefits:

Data coordination:

As an electronics vendor, VSE works with designers to verify all of your design data at the beginning of the project and alert you of any problems. Coordinating design data with just one vendor instead of juggling multiple vendors and managing different data sets allows you to spend more time on the design.

Hardware compatibility:

Employing multiple vendors can sometimes result in undetected compatibility issues once all pieces are brought together late in manufacturing. With the PCB, the wire harness, and the box all built at VSE, customers don’t have to worry about assembly mismatches; VSE develops and tests system components to work seamlessly with the box build.

Troubleshooting:

Coordinating with a single, experienced vendor who understands how electrical components interact while catching and correcting problems saves time in debugging and troubleshooting.

Parallel development process:

VSE synchronizes all design components concurrently, ensuring optimal design between the various elements of the box build.

A box build assembly is more than just an enclosure—it is an integral part of an electronic device. As such, a high level of construction expertise is necessary to fulfill design intent.

Complete Electronics Expertise for a Range of PCB Box Builds

At VSE, customers rely on our expertise and experience to precisely assemble printed circuit boards; that same level of quality goes into our box builds. These PCB box builds assembly services support projects with a range of specifications:

Size:

VSE can handle various forms and sizes, from portable devices to industrial equipment.

Type:

Box configurations can vary from form-fitting packages to enclosures accommodating racks for multiple boards.

Power:

High-voltage capacity ratings can reach 30,000 V.

Terminations:

Board-to-board connections in the thousands are possible.

Electronics:

Most box builds contain PCB assemblies and cable and wire harnesses; VSE can incorporate other OEM electronics into a box build to complete electronic devices, such as power supplies and control panels.

Box Build Assembly with a Quality Emphasis

Throughout product development, you can rest assured that your project will have our complete attention. Here’s a brief glimpse of our process here at VSE:

Sub-Assembly

All items undergo individual testing to ensure operational perfection, starting with the sub-assemblies (circuit boards, wiring harnesses, etc.)

Box Build

Next, the box assembly of the box proceeds bottom-up, with strict attention to design specifications so that labels, wire routing, critically torqued screws, and continuity test points provide inspectability at each level of the build.

Testing

The box is ready for service once project testing is complete according to custom-developed specifications and industry standards.

Trust VSE’s PCB Box Build Assembly Services for Your Next Project

With over 40 years of experience building electronics, we’ve seen and built numerous types of devices to a sterling level of quality and reliability. Rest assured: we have the technical skills and capabilities to create your box-build assembly precisely. We also deeply understand the electrical and safety requirements your box build must adhere to. Our engineering staff and factory technicians are fully trained in applicable industry standards, including UL508a, so you can be confident that your device assembles correctly. Contact us today to learn more about partnering with us for your box-build assembly needs.

If you are looking for a CM that prides itself on its care and attention to detail to ensure that each PCB assembly is built to the highest standards, look no further than VSE. Contact us today to learn more about partnering with us for your next project.