PCB Box Build Assembly Services , PCB Printed Circuit Board Assembly Service

DuxPCB provides comprehensive Box Build Assembly (Systems Integration) services that bridge the gap between electronic manufacturing and mechanical engineering. We take your project beyond the printed circuit board, handling enclosure fabrication, complex cable routing, sub-assembly installation, firmware configuration, and final retail packaging.

For OEMs, managing a Box Build project often means coordinating a fragmented supply chain: PCB vendors, injection molding factories, CNC machine shops, and cable harness manufacturers. This fragmentation leads to communication errors, tolerance mismatches, and logistics delays.

DuxPCB simplifies this chaos into a Single-Source Solution. Whether you need a simple handheld IoT device or a complex industrial control cabinet involving hundreds of parts, our facility operates as your dedicated remote factory, delivering fully tested, finalized products ready for the global market.

Box Build is often mistaken for simple manual labor. In reality, it requires a "Mechatronics" mindset. At DuxPCB, we apply rigorous engineering principles to ensure the mechanical fit is as precise as the electronic function.

You do not need to audit separate mechanical factories. We manage the entire BOM (Bill of Materials) ecosystem:

• Plastic Injection Molding: We handle tooling design and production for ABS, PC, Nylon, and TPE enclosures. We also support Overmolding for rubberized grips and Low-Pressure Molding for waterproofing sensitive electronics.

• Metal Fabrication: Our network includes precision CNC machining (Aluminum/Stainless Steel), Sheet Metal bending, Die Casting, and Extrusion.

• Custom Interconnects: We manufacture custom wire harnesses, flat flexible cables (FFC), and ribbon cables cut to exact lengths with strain relief.

A PCB might work perfectly on the bench but fail inside the box. Before production, our mechanical engineers perform a Tolerance Stack-up Analysis.

• Interference Checks: We verify that tall components (capacitors, connectors) do not collide with the enclosure ribs or heat sinks.

• Mounting Alignment: We ensure PCB mounting holes align perfectly with enclosure bosses to prevent bending stress on the FR4 material.

• Thermal Airflow: We review the enclosure design to ensure adequate airflow for hot components.

We utilize specialized equipment for permanent mechanical bonding:

• Heat Staking: Inserting threaded brass nuts into plastic bosses using thermal presses, ensuring high pull-out strength for screws.

• Ultrasonic Welding: Hermetically sealing plastic enclosure halves without glues or screws, creating a tamper-proof and waterproof bond.

• Potting & Encapsulation: Filling enclosures with Epoxy or Silicone to provide IP67/IP68 protection against vibration, moisture, and reverse engineering.

We have scaled our facility to handle high-mix, high-complexity system integration.

In Box Build assembly, consistency is the hardest metric to achieve. We control the variables using digital SOPs and strict tooling.

Loose screws cause field failures; overtightened screws crack plastics.

• Calibrated Tools: We use electric screwdrivers with torque-locking and screw-counting functions. If a screw is missed or under-torqued, the line stops.

• Threadlock Application: We apply Loctite (Threadlocker) where necessary to prevent loosening under vibration.

"Rat's nest" wiring blocks airflow and pinches cables.

• Routing Jigs: We design dedicated jigs to route cables along specific paths.

• Strain Relief: We apply zip ties, adhesive clips, and grommets to ensure no tension is placed on the solder joints or connectors.

Electronics must function well; products must look perfect. We inspect enclosures based on strict surface classifications:

• Class A Surface (User Facing): Zero scratches, specks, flow marks, or sink marks allowed when viewed at 30cm under 1000 Lux lighting.

• Class B Surface (Side/Bottom): Minor imperfections allowed if they do not affect fit or function.

We treat your product assembly with the same discipline as a semiconductor line.

Phase 1: Supply Chain Consolidation (Kitting)
We aggregate all materials. The PCBA is manufactured in-house, while mechanical parts are sourced and inspected by our IQC (Incoming Quality Control) team for dimensional accuracy and color consistency.

Phase 2: Sub-Assembly Preparation
Efficiency starts here. We pre-cut wires, crimp terminals, install heat-sinks, and pre-assemble LCDs to bezels before the main line.

Phase 3: Main Line Integration
Operators follow visual Digital Work Instructions (DWI) on monitors. The PCB is mounted, cables are connected, and the enclosure is closed.

Phase 4: Firmware & Serialization
We flash the final firmware version. Each unit is assigned a unique Serial Number and Barcode, which is logged in our MES (Manufacturing Execution System) for full traceability.

Phase 5: System Testing & Burn-In
Every unit undergoes a functional check. We also perform "Aging Tests" (running the device for 24-48 hours) to screen out early-life component failures (Infant Mortality).

Phase 6: Final Audit & Packaging
A Final QC (FQC) audit checks the device aesthetics and packaging contents (manuals, accessories) before sealing the box.

Challenge: "Tolerance Stack-up" issues where the PCB doesn't fit the box.
Solution: We request "First Articles" of the enclosure and perform a fit-check with the bare PCB before mass production. If there is a mismatch, we modify the PCB outline or the mold tool immediately.

Challenge: Color inconsistency in plastic parts.
Solution: We use Pantone color matching chips and limit samples. Our IQC rejects any plastic batch that deviates from the approved color master.

Challenge: Firmware version control.
Solution: We implement strict Checksum verification during programming to ensure the correct software version is loaded every time.

Q: Can you handle the sourcing of custom metal molds and plastic injection tools?
A: Yes. We have long-term partnerships with mold makers. You own the mold; we manage the maintenance and production. We can also assist in DFM for the mold to reduce tooling costs.

Q: What files do you need for a Box Build quote?
A: To provide an accurate quote, we need:

1. Gerber & BOM for the PCBA.

2. 3D CAD Files (STEP/IGES) for the enclosure.

3. BOM for Mechanicals (listing screws, wires, glues).

4. Assembly Drawings or Instructions (PDF/Video) showing how you want it built.

Q: Do you perform functional testing for the complete unit?
A: Yes. We highly recommend it. You can provide the test fixture and procedure, or we can design and build a functional test jig (FCT) for you.

Stop managing five different vendors for one product. Let DuxPCB handle the integration complexity so you can focus on sales and marketing.

Send us your 3D Drawings and BOM today. Our mechanical engineers will review your design for assembly efficiency and provide a complete Turnkey Box Build quotation.