The printed circuit assembly (PCA) or printed circuit board assembly (PCBA) has long played a critical role in the creation and functionality of modern electronics, being the main building block for nearly every single modern device across the world. Without PCAs, technology would not have advanced nearly as fast or as far as it has. 

How Printed Circuit Assemblies are made

PCAs are incredibly widespread, found in nearly every device–but the actual assembly of a printed circuit board and all of its components is an intricate task. Printed circuit boards or PCBs serve as the base for the assembly, consisting of a substrate typically consisting of fiberglass or specialized plastic, mounted with the necessary components, and then covered with epoxy and a solder mask for insulation and protection. 

Components are typically added through surface mount technology (SMT) which uses automation to place sensitive and typically small components like resistors or diodes onto the board. For larger components with leads or wires that have to be plugged through holes, through-hole insertion technology (THT) is used, either manual or automatic. 

Once everything has been assembled, the PCA is then tested for proper functionality and inspected for misplaced or missing components and improper connections. If you’re interested in learning more about how printed circuit board assemblies are made, check out our article on the basics!

PCAs–The Cornerstone of Modern Electronics

Printed circuit assemblies are found in just about every electronic device in every industry around the world. They connect the various components of the device together, allowing for communication between them and ultimately allowing the device to function. There are PCAs in smart phones and other smart devices, complex ones in computers and related technology, even in consumer products like refrigerators and microwave ovens. 

More durable PCAs can be found in the engines of aerospace equipment and under the hood of your car, where they are exposed to oil, heat, water, and vibration. They provide critical functionality to braking systems, flight control operations in environments where electronics typically would not function properly. They’re vital in the healthcare industry, allowing for the development of life-changing and even life-saving technologies. These days, more often than not, nearly any electronic device has some sort of PCA built into it, whether simple or complex, for smoother operation and more efficient functionality. 

Cypress Technologies–Helping Our Partners Push the Boundaries of PCAs

Cypress Technologies has been an electronic manufacturer since the 80s, and we’ve seen firsthand how quickly the marketplace can change and how fast technology has advanced. We are a full-service contract manufacturer for the electronics industry, providing engineering and design services as well as a wide range of box build manufacturing, PCB assembly, electromechanical and harness assemblies, and much more. 

Are you looking for an expert electronics contract manufacturer? Consider working with us! We are dedicated to our customers, leveraging a large procurement system and our extensive industry experience to provide them with solutions tailored to their needs. Check out our website to contact us or learn more!

With the rapid pace of the market and the ever-evolving landscape of the high-tech industries, the ability to get a turnkey PCB assembly is more critical than ever. When a manufacturer offers ‘turnkey’ solutions, that means that they handle everything–design, sourcing, fabrication, installation, aftermarket support, and technical service. Also known as end-to-end manufacturing, turnkey support provides you with a product that’s ready for operation. 

Why is turnkey manufacturing optimal for PCBAs?

Nearly any contract electronics manufacturer offers PCB manufacturing and assembly services these days. However, there are many more advantages to working with a manufacturer that handles everything for you, from assembly to the actual installation of the PCB into a box build or other system. 

One Point of Contact

The biggest advantage for working with one manufacturer for the entirety of the project is just that–you only have to communicate and collaborate with one manufacturer. This eliminates the stress of having to coordinate the project between multiple manufacturers, trying to maintain the same timelines with all of them, and getting all of them to connect when needed on the project. 

Consistent Quality

Having a single point of contact for the project also ensures that each phase is synchronized from start to finish, and allows for any necessary changes to be made much more quickly. With multiple suppliers, there is no guarantee that they have the same quality management system, that their systems are compatible with each other, or that they even uphold the same standards of quality. With turnkey PCB assembly, there is far less likely to be errors due to miscommunication, system compatibility, and differences in quality control. 

Efficient Production

In turnkey manufacturing, the company that makes your PCB will source everything for you. This reduces shipping time and costs between supplies, keeping it all going to and from one facility, and also improves the efficiency and quality of the final product. If there are any problems or defects, they can be corrected quickly because the people who engineered the board are already right there. Plus, there’s no waiting between different phases of the project as the products are shipped from one company to another. 

Turnkey PCB Assembly at Cypress Technologies

Cypress Technologies is an expert manufacturer of all different types of electronic and electromechanical assemblies. We assist our customers from product design and development to the delivery of a finished product and everything in between. Our services include engineering and design, box and panel assembly, testing and text fixture design, cable and harness assembly, troubleshooting and repair, PCB assembly and ruggedization, and much more. If you’re looking for a contract electronics manufacturer that can provide you with a turnkey solution, then check out Cypress Technologies today!

One of the major services that we offer at Cypress Technologies is box build manufacturing, the assembly of all of the fabricated components that we’ve made and/or procured into a full, finished system. That also includes maintaining a strict adherence to the values that resonate with our clients and their own customers, as well as ensuring ethical business and manufacturing practices throughout our shop. We don’t just provide our customers with a product–we give them an assurance that they are receiving uncompromising quality. 

So what is box build assembly?

On our blog and our website, we have discussed our box build manufacturing and assembly services–but what is box build assembly? This term is commonly used to describe the entire manufacturing process of putting together a PCB assembly and harness system within an enclosure. That includes PCB component manufacturing and assembly, and the arrangement and installation of a cable harness, power source, PCBs, and any other vital components into a fabricated enclosure or ‘box’. 

The main focus of a box build is often the custom enclosure, typically made from fabricated sheet metal. Having a custom enclosure built is important, especially to ensure that all components are assembled within the ‘box’ in a way that is optimal for performance and efficiency, and allows the system to be integrated into the larger product. Once the enclosure is made, many components are then carefully assembled within it, according to the design previously developed. 

Providing High Quality and Ethical Box Build Assemblies

At Cypress, we offer everything you need for box build assembly services, from engineering and design capabilities to custom machining for enclosures and other metal and plastic components, to full PCB component assembly. We also adhere to strict conflict materials policies and extensive documentation to ensure that all materials used in our facility originate from socially and environmentally responsible sources. 

Part of the responsibilities of our quality assurance team is vendor and material management–we take several measures to ensure that any material that goes into our customers’ box builds is both the best quality, and also adheres to their business requirements and values. 

In August, the U.S. SEC issued the final, updated conflict minerals rule, which requires publicly traded companies to report annually the presence of conflict material originating in ‘Covered Countries’. Cypress Technologies supports the goal of ending violence, human rights violations and environmental devastation in the Covered Countries, and we strictly comply with any requirements applicable to our Company under the Conflict Minerals Rule.

Interested in partnering with Cypress Technologies?

If you’re looking for an expert and responsible box build manufacturer, then look no further! Cypress Technologies has offered a wide range of custom electronics manufacturing services since 1987, and we have a long history of integrity and long-term vendor relationships to offer you. Check out our website to learn more and contact us today!

Box build assemblies are an integral part of custom electronics manufacturing. Rather than sourcing the various components of the assembly to different manufacturers–such as the PCBs, cables, and enclosure–everything is sourced, made, and assembled by one supplier. Typically, each part of box build manufacturing is customized specifically to meet customer requirements. That includes not just the various components of the assembly, but also the function as well, ensuring that the final product will be compatible with the customer’s existing systems and will ensure that those systems run as smoothly and efficiently as possible. 

Cypress Technologies specializes in particularly complex or challenging box build assemblies, offering custom builds according to our customers’ needs. We offer what we call end-to-end solutions, providing everything from component sourcing to final assembly and testing, all under one roof. This allows us to provide a high quality and cost effective product that is specifically designed to meet the unique requirements of the customer. 

Expert Service from Start to Finish

Cypress offers expert solutions for high-value box build assemblies that are typically difficult to create and require extensive testing and inspections. We work closely with our customers throughout the entire process to ensure that we provide them with the best possible product for their needs. 

1. Design and Prototyping

Whether you have a fully-fledged design or you want assistance to develop a product concept, our experts offer their knowledge to conceptualize, design, and prototype the box build. The engineering team works closely with our manufacturing team to ensure the design will translate well into a physical prototype. 

2. Material Sourcing

Cypress Technologies utilizes an elite procurement system that manages pricing for over fifteen hundred vendors around the world. We offer our customers extensive negotiating power on material availability, component features, and pricing, so that they can get the best possible value. Our system uses a combination of MRP, Lean, and JIT tools as well, in order to bridge the gap between what’s on paper and the actual market demand. 

3. Expert Manufacturing

Cypress has one of the most experienced teams of electronics manufacturers in the country, with decades of combined experience in the industry that we can offer. We are a one-stop shop, accommodating PCB, Cable & Harness, and Electromechanical assemblies in addition to box builds. We also offer custom machining of metals and plastics in-house to ensure that whatever components that need to be included in the assembly are available. 

4. Quality Assurance and Inspections

In addition to manufacturing and assembling box builds for our customers, we also are highly experienced in testing and test fixture designs. We’ll perform a wide range of quality inspections such as troubleshooting, repairs, and failure analyses to ensure that the final product meets with customer requirements. In addition, we offer full program documentation for material traceability and data integrity. 

Looking for a supplier of box build manufacturing services?

Cypress Technologies has been offering proven electronics manufacturing solutions since 1987. Check out our website to request a quote or learn more. 

Box build assemblies are a specialty of Cypress Technologies. These assemblies are crucial components of electronic products, efficiently integrating multiple electronics components into one housing for a completed and functional product. Also called system integration, box builds include the process of designing, producing, and constructing everything from a simple PCBA to a cabinet housing a highly complex electromechanical system.

There are a wide variety of components that could be included in a box build assembly, but the basic components are always the printed circuit board or boards, wiring harnesses connecting them, power supplies, connectors, and other hardware. All of this is integrated and mounted into the enclosure or frame that houses the assembly. This final product can then be installed into the final end-use product, be it construction or mining equipment, machines for alternative energy, industrial controls, and much more.

The Different Quality Standards for Box Builds

There are various standards that guide box build and PCB production and assemblies, but the most complex, and the specialty of Cypress Technologies, are those that meet the IPC manufacturing standards for electronics production.

IPC 610 guides the production of PCBs in three different classes: One for General Electronics, Two for Dedicated Service Electronics, and Three for High-Reliability Electronics such as those used in military or aerospace applications. Cypress builds circuit boards to these strict manufacturing standards and test requirements, and those boards are often further incorporated into box build assemblies.

The IPC 620 standards are what guide the production of specialty box builds, and follow the same three classes as the 610 for PCBs. These types of assemblies typically are very complicated, both in the standards that they have to meet and the levels of assembly they involve. IPC 620 Class III box builds are especially complex, including PCB assemblies, cables, wire harnesses, machined parts and modified boxes, custom components and complex enclosures. They also include strict testing requirements due to the end-use applications that these assemblies will fulfill.

In addition, every electrical component or electronics product in the United States and beyond almost always has to meet the UL, ETL, or some similar standard for user and consumer safety. This often requires a highly regulated certification process to ensure that products are compliant with the industry standards under which they fall.

The Process

Box builds involve significant collaboration between design engineers, sourcing specialists, and technicians in order to correctly integrate all components together in a way that is efficient with the given space, promotes the function of the final product, and maintains that function for a long time.

1. Design

The product’s specifications, features, requirements, and final functionality are defined and the assembly and manufacturing instructions are created. 

2. Sourcing

All of the necessary products are sourced. At Cypress, this can include sourcing for any printed circuit boards that we will be making as well as connectors, switches, displays, cables, battery packs, and necessary hardware.

3. Pre-Assembly Prep

The enclosure that will house the assembly is prepped, along with any fasteners, brackets, or other mounts. 

4. Installation

Once the PCBs are assembled, they are integrated into the housing along with any other electronic components according to the assembly instructions, and secured in place. 

5. Cable & Wire Harness

Now that all of the electronic components are installed into the enclosure, the cables and wires are routed through the box to connect them as per the initial instructions in a way that prevents interference and ensures proper cable management. 

6. Integrating the Power Supply and Final Mechanical Assembly

Next, all power supplies are integrated into the assembly, along with any mechanical parts such as covers and structural components. 

7. Software Loading and Testing

If necessary, any software or firmware is loaded into the assembly, and then the entire product is calibrated and tested to ensure that everything is working as intended. The final product is inspected for any defects or discrepancies to ensure that the product meets any quality standards. 

Box Builds at Cypress

Cypress has integrated Lean manufacturing practices throughout our business in order to deliver each product with high quality and efficiency. We utilize one of the most elite procurement systems that allows us to connect with and manage the pricing for hundreds of vendors all over the world, allowing us to offer greater negotiating power to our customers on availability, features, and pricing. We have a system in place as well that anticipates any potential changes that might come up during a project, and safely manage it for a seamless and efficient manufacturing process. 

Interested in learning more about our process? Check out our website to learn more about how Cypress Technologies can help you.