Box Build & System Assembly
Enclosure fit-out, mechanical and electrical integration, firmware loading, functional test and retail-ready packaging — a finished product, not a subassembly.
Finished goods
The last mile of manufacturing, owned by one supplier
Box build is where separately-good parts turn into a product that either works or does not. It needs the boards, the harnesses, the enclosure, the labels and the firmware to converge on one line, on the same day, in the right revision.
We hold that convergence. The PCBAs, cable assemblies, sheet metal, plastics and bought-in modules are all scheduled against one build date, integrated to a controlled work instruction, tested as a system and packed the way your customer expects to receive it.
Get a quote- Sub-assembly kitting with revision control across every part
- Sheet metal, extruded, moulded and rack enclosures
- Firmware and configuration loading with per-unit serial records
- System-level functional, burn-in and safety testing
- Serialisation, asset tagging and country-of-origin labelling
- Retail, industrial and drop-tested export packaging
Capabilities
System assembly capability
Industrial controllers, instrumentation, medical devices, EV charging units, telecom cabinets and consumer hardware.
Enclosure integration
Panel mounting, DIN rail, backplane and rack builds in sheet metal, aluminium extrusion and injection-moulded housings.
Electro-mechanical build
Harness routing, connector mating, torque-controlled fastening, gasket and seal fitting to a controlled work instruction.
Configuration
Firmware flashing, calibration constants, MAC and licence key programming, with each step logged against the serial number.
System test
Powered functional test, burn-in, hipot and earth-bond, environmental screening and final quality audit.
Build records
As-built BOM per serial number, test results and traveller history retained for the agreed period.
Pack and ship
Custom foam and corrugate, drop-test validation, accessory kitting, and direct-to-end-customer fulfilment.
Technical envelope
What our network can build
Typical limits across the qualified supplier base. Outside this envelope? Ask — the network is wider than the table.
| Parameter | Range |
|---|---|
| Product size | Handheld units up to full 42U cabinets |
| Enclosure types | Sheet metal, extrusion, moulded plastic, die-cast, 19-inch rack |
| Fastening | Torque-controlled driving with data capture on critical joints |
| Programming | In-system firmware load, calibration, MAC/serial provisioning |
| System test | Functional, burn-in, hipot, earth bond, IP verification |
| Serialisation | Barcode, QR and RFID with per-unit as-built records |
| Packaging | Retail, bulk, ESD-safe and ISTA-tested export packing |
| Batch size | 10-unit pilot runs to 25,000+ per year |
| Pilot build lead time | From 10 working days after kit availability |
How it runs
From enquiry to delivered product
Product handover
Assembly drawings, work instructions, test spec, packaging spec and the current BOM revision.
Line and kit planning
Every sub-assembly scheduled to one build date, with revision control across boards, cables and mechanics.
Pilot build
A small run to prove the work instruction, cycle time and test coverage before volume is committed.
Volume assembly
Built to the signed work instruction with in-process checks at each station.
System test and audit
Powered test, burn-in where specified, and a final quality audit against your acceptance criteria.
Pack, serialise, ship
Packed to spec, serial records uploaded, shipped to your warehouse or straight to your customer.
Do you have a project we can help with?
Send your BOM, Gerber files and drawings — you get a costed, capability-matched quote back.
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