Complete Box Build Assembly Checklist for OEMs in 2026
The definitive checklist for Australian OEMs outsourcing box build assembly. From pre-assembly verification to final testing and documentation, ensure your electronic enclosures meet IPC-A-610 and AS/NZS standards.
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Request ChecklistBox build assembly failures are expensive. A single missing checklist item can lead to field failures, warranty claims, and damaged reputation. After 18 years building complete electronic assemblies for Australian OEMs, we've seen every possible mistake — and created this checklist to help you avoid them.
Most Common Box Build Failure
70% of box build failures we see are caused by incomplete documentation or miscommunication between design and manufacturing teams. The second most common issue? Skipping first article inspection to save time — which always costs more in the long run.
Whether you're outsourcing box build for the first time or looking to improve your existing process, this checklist covers everything from component verification to final testing and documentation.
What is Box Build Assembly?
Box build assembly (also called systems integration or electromechanical assembly) is the process of building complete electronic products by integrating multiple components into a finished, ready-to-ship unit.
Box Build Typically Includes:
PCBA Integration
Installing printed circuit board assemblies into enclosures
Wire Harness Assembly
Custom cable assemblies connecting boards and components
Enclosure Fabrication
Chassis, panels, and mounting hardware
Mechanical Components
Fans, power supplies, displays, and controls
Cable Routing & Dressing
Proper cable management per IPC/WHMA-A-620
Final Testing
Functional, electrical, and safety testing
Labeling & Marking
Serial numbers, safety labels, and certifications
Packaging & Shipping
Protective packaging and logistics
Box Build vs PCB Assembly
PCB assembly is just one component of box build. Box build takes populated PCBs and integrates them with enclosures, wire harnesses, and other components to create a complete, functional product. If your customer receives a finished unit in a box rather than just a circuit board, that's box build.
Pre-Assembly Checklist: 10 Critical Items
Complete these checks before starting assembly to avoid costly delays and rework:
BOM (Bill of Materials) Accuracy
Verify BOM matches assembly drawings. Check part numbers, quantities, and revision levels. Ensure all components are approved equivalents.
Component Availability & Inspection
Physically verify all components are in stock and meet specifications. Inspect for damage, contamination, or incorrect parts.
PCBA Quality Verification
Inspect PCBAs for IPC-A-610 compliance. Check for soldering defects, component placement accuracy, and proper labeling.
Learn about IPC-A-610 standardsAssembly Drawings & Work Instructions
Ensure current revision of assembly drawings, cable routing diagrams, and work instructions are available on production floor.
Enclosure & Hardware Verification
Check chassis dimensions, hole positions, threaded inserts, and surface finish. Verify all mounting hardware and fasteners are correct type and quantity.
Wire Harness Pre-Check
Test wire harnesses for continuity, insulation resistance, and proper termination. Verify connector mating, strain relief, and labeling.
Wire harness quality standardsTest Equipment Calibration
Verify all test equipment is within calibration period. Check test fixtures are configured correctly for this product.
Our testing capabilitiesTooling & Fixturing
Confirm all required tools, torque wrenches, and assembly fixtures are available and in good condition.
Quality Plan & Inspection Criteria
Review inspection points, acceptance criteria, and documentation requirements. Ensure QC team understands requirements.
Quality certificationsFirst Article Inspection Plan
Prepare FAI checklist and documentation package. Schedule time for engineering review of first unit before production run.
Pro Tip: The 80/20 Rule
Items marked as "critical" (01, 02, 04, 10) account for 80% of pre-assembly issues we see. If you only have time to double-check four things, make it these four. They catch the majority of problems before they become expensive.
Design for Manufacturability (DFM) Tips for Box Builds
Good DFM can reduce assembly time by 30-50% and significantly improve reliability. Our design team works with OEMs to optimize designs before production:
Mechanical DFM
- Minimize fastener types: Use one or two screw types maximum to reduce assembly time and tool changes
- Captive hardware: Use cage nuts, PEM fasteners, or captive screws to prevent dropped parts
- Assembly access: Ensure technicians can reach all fasteners and connectors without disassembling other components
- Alignment features: Add locating pins, tabs, or guides to ensure correct component positioning
Electrical DFM
- Test point access: Design easily accessible test points for all critical signals and power rails
- Keyed connectors: Use polarized connectors to prevent incorrect mating (saves hours of troubleshooting)
- Labeled wire harnesses: Clearly mark both ends of every cable with permanent labels
- Strain relief: Design cable routing with adequate length for strain relief per AS/NZS 3000
Cable Routing DFM
- Minimum bend radius: Allow 6-10x cable diameter for routing (per IPC/WHMA-A-620)
- Cable tie mounts: Include built-in cable tie anchors every 150-200mm along cable paths
- Separate power/signal: Route high-current cables away from sensitive signal lines (minimum 25mm separation)
- Avoid sharp edges: Use grommets or edge protection where cables pass through metal openings
Serviceability DFM
- Modular design: Make common failure components (power supplies, fans) easily replaceable
- Quick-connect cables: Use connectors instead of soldered connections for field serviceability
- Visual indicators: Include status LEDs visible from outside enclosure for troubleshooting
- Documentation labels: Include assembly revision and date labels inside unit for traceability
Free DFM Review for Australian OEMs
Our engineering team provides complimentary DFM reviews for box build projects over 100 units. We'll identify assembly challenges, suggest design improvements, and provide cost-saving recommendations before you commit to tooling.
Request DFM ReviewCommon Box Build Components & Considerations
| Component Type | Key Considerations | Common Issues |
|---|---|---|
| PCBAs (Printed Circuit Board Assemblies) | IPC-A-610 compliance, conformal coating, mounting orientation, thermal considerations | Insufficient standoff height, damaged traces during mounting, ESD damage |
| Wire Harnesses | IPC/WHMA-A-620 standards, minimum bend radius, strain relief, proper labeling | Excessive cable length, sharp bends, inadequate strain relief, unlabeled cables |
| Enclosures / Chassis | Material (aluminum, steel, plastic), IP rating, thermal management, EMI shielding | Dimension tolerances, hole misalignment, poor grounding, inadequate ventilation |
| Power Supplies | Voltage regulation, efficiency, thermal dissipation, safety certifications (RCM) | Undersized for load, poor ventilation leading to thermal shutdown |
| Cooling Fans | Airflow (CFM), noise level, bearing type, voltage, replaceable filters | Reversed airflow direction, blocked intake/exhaust, vibration noise |
| Connectors (External) | IP rating, current rating, mating cycles, proper panel mounting and sealing | Incorrect torque on backshell, damaged seals, cross-threaded housings |
| Displays / HMI | Viewing angle, touchscreen calibration, environmental rating, cable interface | Fingerprints/scratches on screen, poor visibility in sunlight, unsealed gaps |
| Fasteners & Hardware | Material compatibility (avoid galvanic corrosion), torque specifications, locking features | Mixed fastener types, over-torqued screws causing thread damage, missing washers |
Australian Climate Considerations
Box builds deployed in Australian conditions face unique challenges: extreme heat (45°C+ in mining/outback), high humidity (coastal/tropical regions), dust ingress (mining, agriculture), and salt spray (marine environments). Always specify environmental requirements early in design phase.
Quality Control Checkpoints During Assembly
Implement these inspection points during assembly to catch defects before final testing. Our CNAS & ISO 17025 certified quality team follows these checkpoints on every box build:
First Article Inspection (FAI)
Timing: Before production run
- 100% dimensional verification against drawings
- Complete BOM verification (every component)
- Functional testing with detailed documentation
- Engineering sign-off before proceeding to production
PCBA Installation Inspection
Timing: After board mounting
- Correct orientation and positioning
- Proper standoff height (minimum 6mm clearance)
- Secure mounting (all screws torqued per spec)
- No mechanical stress on boards or components
Wire Harness Routing Inspection
Timing: During cable installation
- Minimum bend radius maintained (6-10x cable diameter)
- Proper strain relief at all connectors
- No interference with moving parts or sharp edges
- Cable ties at proper intervals (150-200mm), not over-tightened
Connector Mating Inspection
Timing: After all connections made
- Positive engagement (audible click/visual confirmation)
- Proper backshell torque (use torque wrench)
- No bent pins or damaged housings
- All locking mechanisms engaged
Visual Inspection (IPC-A-610)
Timing: Before enclosure closure
- No foreign object debris (FOD) inside enclosure
- All labels present and legible
- No damaged insulation or exposed conductors
- Thermal interface materials properly applied
Pre-Test Inspection
Timing: Before electrical testing
- All covers/panels properly installed
- All connectors verified mated
- Power supply voltage set correctly
- Test equipment calibrated and ready
Testing Requirements for Box Build Assemblies
Comprehensive testing is critical for box build quality. Our testing facility performs these tests on every production unit:
Electrical Testing
1. Continuity Testing
- •Verify all connections per schematic
- •Check for opens and shorts
- •Typical resistance: <1 ohm for good connection
2. Insulation Resistance (Megohm) Test
- •Test voltage: 500V DC (per AS/NZS 3000)
- •Minimum acceptable: 10 MΩ (higher is better)
- •Critical for safety and regulatory compliance
3. High-Pot (Hi-Pot) Testing
- •Required for AC-powered equipment
- •Test at 2x rated voltage + 1000V for 1 minute
- •Leakage current must be within specification
Functional Testing
1. Power-Up Test
- •Verify correct voltage at all power rails
- •Check current draw within expected range
- •No smoke, unusual odors, or excessive heat
2. Operational Testing
- •Run through all operational modes
- •Verify all inputs and outputs function correctly
- •Check communication interfaces (RS485, Ethernet, etc.)
3. Burn-In Testing (Optional)
- •Run at full load for 24-72 hours
- •Identifies infant mortality failures
- •Recommended for critical or high-reliability applications
Environmental Testing
- Temperature Cycling: Test operation at minimum and maximum rated temperatures
- Vibration Testing: Per MIL-STD-810 or IEC 60068-2-6 for mobile equipment
- IP Rating Verification: Dust and water ingress testing per IEC 60529
- Salt Spray (Marine): ASTM B117 testing for marine/coastal applications
Safety & Compliance Testing
- Earth Continuity: Verify ground connection <0.1 ohm resistance
- Touch Current Test: Per AS/NZS 3100 for electrical safety
- EMI/EMC Testing: CISPR 22 / EN 55032 for electromagnetic compatibility
- RCM Certification: Required for all electrical equipment sold in Australia
Testing Standards Reference
Electrical Workmanship:
IPC-A-610 (Acceptability of Electronic Assemblies)Wire Harness Standards:
IPC/WHMA-A-620 (Cable and Wire Harness)Australian Electrical Safety:
AS/NZS 3000 (Wiring Rules)Documentation Requirements for Box Build
Complete documentation is essential for traceability, warranty support, and regulatory compliance:
Required Documentation (Per Unit)
- Serial number and build date
- Bill of Materials (BOM) with revision level
- Assembly drawing revision used
- Test results (continuity, insulation, functional)
- QC inspection sign-off
- Component traceability (lot codes)
- Calibration certificates for test equipment
- Non-conformance reports (if any deviations)
First Article Inspection (FAI) Package
- Complete dimensional inspection report
- BOM verification (100% component check)
- Detailed photographs of assembly
- Functional test results with data
- Engineering evaluation and sign-off
- Any design changes or ECOs documented
- Comparison to customer specifications
- Recommendation for production release
Digital Documentation & Traceability
We maintain complete digital records for every box build assembly, including:
7-Year Record Retention
Full traceability for warranty and compliance
Serial Number Lookup
Instant access to build records by serial number
Certificate of Conformance
Provided with every shipment
Frequently Asked Questions
What is box build assembly?
Box build assembly (also called systems integration or electromechanical assembly) is the process of building complete electronic products by integrating PCBAs, wire harnesses, enclosures, and mechanical components into a finished unit. It goes beyond PCB assembly to include chassis assembly, cable routing, final testing, and packaging.
What certifications are required for box build assembly in Australia?
Australian box build assemblies typically require AS/NZS 3000 compliance for electrical safety, IPC-A-610 Class 2 or Class 3 for workmanship standards, and IPC/WHMA-A-620 for cable and wire harness assemblies. Medical devices need TGA registration, while industrial equipment may require RCM (Regulatory Compliance Mark) certification.
How long does box build assembly take?
Lead times vary by complexity. Simple box builds with readily available components can take 2-3 weeks. Complex systems requiring custom enclosures, specialized testing, or regulatory approval may take 8-12 weeks. Prototype builds typically take 1-2 weeks for initial units.
What is Design for Manufacturability (DFM) for box builds?
DFM for box builds involves designing products that are easy to assemble, test, and service. This includes minimizing fastener types, ensuring adequate cable routing space, using standard components where possible, and designing for accessible test points. Good DFM reduces assembly time by 30-50% and improves reliability.
Do you provide box build services for prototypes?
Yes, we handle everything from single prototype units to full production runs. Prototype box builds are ideal for design validation, testing, and customer demonstrations before committing to volume production. We can also assist with DFM improvements based on prototype assembly experience.
What is the difference between IPC-A-610 Class 2 and Class 3?
Class 2 is for general electronic products where cosmetic imperfections are acceptable if functionality isn't affected. Class 3 is for high-reliability applications (medical, aerospace, military) requiring the highest level of workmanship with minimal defects. Class 3 has stricter criteria for everything from solder joints to wire routing.
Ready to Start Your Box Build Project?
With 18 years of experience building complete electronic assemblies for Australian OEMs, we deliver quality box builds that meet IPC-A-610, AS/NZS 3000, and your custom requirements. Our CNAS & ISO 17025 certified facility ensures every unit meets specification.
Full Box Build Services
From PCBA to finished product
IPC-A-610 Class 2/3
Certified quality standards
Free DFM Review
Optimize for manufacturing
Complete Testing
Electrical, functional, environmental
Custom Design Support
Engineering assistance available
Fast Prototypes
1-2 week turnaround
Download the complete checklist: Request our free printable box build assembly checklist PDF by contacting us above.
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