Finished Products Box Build Assembly
Fully Functioning Electronic Assemblies: From PCBAs to Turnkey Box Builds and Finished Products
For many customers, a finished product requires more than just a printed circuit board assembly. As a full-service electronics contract manufacturer, CO-AX designs and produces fully functioning electronic assemblies and turnkey box builds that integrate PCBAs with a wide range of components to deliver market-ready products.
Our box build manufacturing expertise transforms individual elements into complete, operational units. We skillfully combine PCBAs, semiconductors, and integrated circuits with structural elements like enclosures and mounting hardware. Our assemblies incorporate essential connectivity components, power systems, and user interface elements to create sophisticated electronic products.
When you bring your project to CO-AX, we start with a thorough design evaluation to ensure your product is Designed for Manufacturability (DFM) and cost-effectiveness. Your project then moves to our dedicated supply chain team for a Bill of Materials (BOM) review to address any obsolescence issues. Once complete, we progress through prototyping and comprehensive testing, including In-Circuit Testing (ICT) and Functional Circuit Testing (FCT), before moving to full production.
Our process covers everything from component selection and integration to final testing and packaging. We handle the entire journey, from initial concept to a finished product ready for market distribution, all from our facility in the USA.
Integrated Design and Contract Manufacturing Services for the Utmost Quality
CO-AX owns and operates a 114,00 SF facility in Cleveland, Ohio that includes cells for finished product assembly, a cable and harness assembly area, multiple Surface Mount Technology (SMT) lines, through hole assembly (THT), wave and selective soldering, in-circuit and functional testing, automated optical inspection (AOI), conformal coating and more. By embracing the latest automation technologies, we consistently enhance productivity, control costs, and deliver exceptional quality products designed to meet each customer’s unique needs.
In-house design engineering, manufacturing, and supply chain teams use industry-leading software, including Altium, SolidWorks, and SiliconExpert, to assess your document package and mitigate risks. Our expertise in DFM, combined with our product development experience in consumer, medical, aerospace, industrial, and smart devices, reduces your time from concept to production and maximizes your profits.
Our Quality Management System is certified to ISO 9001 and ISO 13485, along with a long list of other regulatory and international standards. Every step in our process is meticulously controlled and fully traceable.
We go above and beyond daily to ensure our customers’ complete satisfaction. Our core values of transparency, integrity, and accountability are ingrained in everything we do. At CO-AX, we are committed to providing the highest quality products that meet and exceed your exacting requirements.
Our advantages include:
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Finished Product, Box Build, and Circuit Board Enclosure Capabilities
- Complete PCBA, Cable, and Enclosure Assemblies
- System Development and Testing
- Efficient Cell-Based Integration
- Merchandise Assembly, Kitting, and Packaging
Customer Success Stories
This customer asked CO-AX to manufacture a box build assembly onshore. Their current contract manufacturer was overseas and had long lead times on orders exceeding 25,000 pieces. The product was costly and did not function as desired.
CO-AX developed a prototype box build that performed precisely as required. We lowered the customer’s costs by more than 60%, reduced the lead times, and provided flexible order quantities – vastly improving the customer’s profit margins and time to market.
What Are the Processes of Box Build Assembly for Finished Products?
Many times the finished product/box build begins with an enclosure – the outer container that holds all the electronic circuitry that makes a product function to specifications. Boxes can be plastic or metal, adorned with a company logo or nondescript, and in some cases, as with a modem, for example – the box is the finished product itself. The enclosure must be sized appropriately to house the required printed circuit board assemblies, cables, harnesses, and other components. It must also be constructed to accommodate any harsh environments or other use cases requiring special design considerations.
The components that go into the box build itself are specified, laid out, and typically include a set of work instructions for assembly. Qualified assemblers then utilize these work instructions to build the components inside the box, creating the necessary connections for the circuitry to operate as intended. It is critical that these assemblers follow ISO-certified quality management processes and procedures to ensure the final box meets all specifications. Finished products for the medical industry require manufacturers of Class I and II medical devices also have an ISO 13485-certified quality management system.
Testing is recommended for the PCBAs individually, and then a functional test on the final assembled unit is completed. Designing and developing this test can be accomplished by a contract manufacturer, collaboratively with the OEM’s engineering and design team, or solely by the OEM.
Finally, the finished product is packaged into a specified container for shipping to the OEM or the end user. When going directly to the user, the packaging may also include documentation, such as user manuals, installation instructions, power adaptors and other materials to facilitate the use of the product.
What is a box build assembly in PCB electronics?
A box build assembly in PCB electronics encloses printed circuit board assemblies (PCBAs), cables, and wiring within a protective housing to create a finished product. This turnkey approach involves designing, prototyping, assembling, and testing the entire system inside a box or enclosure that safeguards the electronic components. Box build assemblies consider factors such as size requirements, material selection, environmental conditions, connection layouts, and compliance with industry regulations.
A turnkey box build manufacturer centralizes the entire assembly process under one roof, from PCBA manufacturing through testing and final shipment. This integrated approach eliminates the need to coordinate multiple suppliers for different components, reducing paperwork, simplifying logistics, and accelerating time-to-market. For more detailed information about box build/finished product assembly services and considerations, explore our information on turnkey box build assembly.
What is the difference between box build and PCBA?
The key difference between box build and PCBA lies in their scope and completeness as manufacturing processes. PCBA (Printed Circuit Board Assembly) refers specifically to populating a printed circuit board with electronic components and soldering them in place, focusing solely on creating a functional circuit board. A box build, however, is a more comprehensive process that incorporates the PCBA as just one component within a finished product, adding cables, harnesses, enclosures, displays, and connectors to create a finished product ready for end use.
While PCBAs contain the core electronic functionality, they aren’t typically usable as standalone products without proper housing and connections. Box builds address considerations beyond the circuit board itself, including enclosure design, environmental protection, weight distribution, and final product functionality. The box build process essentially takes the PCBA and transforms it into a complete, protected, and user-ready finished product.
Learn more about how turnkey box build assembly can streamline your electronics manufacturing process in our detailed guide.
