The Intricacies of Box Build Assembly: A Detailed Overview

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.