SOLUTION

Box Build Assembly

ESCATEC specialise in the production of complex sub-assemblies and finished, tested, products. We offer turnkey electronics, mechatronics, cabinet assembly, full system integration and test solutions.

Two hands wearing white gloves placing an electronic component on a rectangular green printed circuit board mounted inside a small white plastic casing.

A row of part-built gas measurement desktop machines consisting of multiple green PCBAs, cable assemblies and precision metalwork waiting for the next stage of assembly.

Two black metal enclosures housing green PCBAs with cables assembled.

A close up of two hands wearing white gloves assembling part of a white hand-held medical device on a bench in front of test equipment and a black box with an ESCATEC sticker on it.

A close up of a green PCBA consisting of lots of semiconductors and wires along with a large black heatsink and fan assembly.

A female production operative wearing blue clothing working on the assembly line surrounded by large black kiosks with touchscreen displays.

Two male production operatives working together holding the top half of a wooden packaging crate preparing to securely package a large and heavy electrical appliance sitting on a wooden pallet.

Close up image of the rear of a complex desktop computer control system showing lots of electronic connector ports and cables.

A close up image of a man picking up a black metal enclosure with five connector ports on the back.

The term 'box build' can mean different things to different people, from fitting PCBAs into simple enclosures with interfaces and displays to complex machines consisting of thousands of individual parts. Complementing our PCB assembly services, ESCATEC's box build assembly services are part of a comprehensive array of electronic, mechatronics, cabinet assembly, and full system integration services.

Most of the box builds we undertake incorporate at least one printed circuit board assembly, and we manufacture a wide range of custom cable solutions at both prototype and production volumes in-house. Whether you need a small PCB assembled into a plastic enclosure or a large front panel equipped with a display, full harness, connectors, switches, fuses, etc., we can help.

ESCATEC's box build assembly and mechanical engineering capabilities are integral to our turnkey electronics manufacturing solutions. Our team has decades of engineering and production experience delivering small and medium sized ‘benchtop’ products through to custom cabinets and kiosks.

Our box build capability and supply chain experience includes:

Plastic and metal enclosures

PCBA integration

Touch screen display units

Optical readers

Bar code scanners

Wiring looms and cable harnessing

Backplanes

Sub-modules

Complex mechatronics assembly

Electro-pneumatic assembly

Heat management and ventilation

High voltage installation and test

Software load and test

Agile production tailored to your needs

We offer fully tailored, flexible, configure-to-order, system integration and test services. We have considerable expertise in setting up flexible lean lines, across our global facilities and creating custom packaging solutions to ensure products work right first time, out of the box.

The lean lines we set up provide a total turnkey manufacturing environment for highly configurable, complex, box build products. They are typically two to ten position, fast changeover lines, that can deliver a responsive solution when demand is dynamic, but lead-times are short.

Our purchasing, logistics, inventory control and production engineering groups work together to deliver the highest levels of service in a demanding part of the electronics manufacturing services sector. We have a track record of excellence for on-time/in full (OTIF) delivery.

Our global manufacturing facilities can offer you lean process design, leading to dedicated production lines or flexible cell manufacturing, incorporating assembly, test and packing with full traceability. This is supported by extensive engineering expertise in electronics, electrical, and mechanical assembly. All production processes, and dedicated production fixtures can be designed and made as required.

Control Cabinet Assembly & Panel Wiring

ESCATEC provides a broad range of options for customers requiring rack system development, from single front panel assembly to a full custom control cabinet. Renowned as a quality, right first-time service, our rack systems expertise means we can procure all necessary components.

Our teams take client technical drawings and specifications to develop fully integrated rackmount solutions. A high level of accuracy means we capture every detail of your control cabinet configuration and hardware, so our service is ideal when multiple identical cabinet installations are required. We can also customise control cabinet enclosures with safety glass, mesh and steel ventilated doors, cable access and power management.

Whether you need controllers, switches, timers, encoders, machined, fabricated metalwork or even plastic products, we will co-ordinate the entire supply chain for you and deliver guaranteed traceability.

We support manufacturers across a range of market sectors with a variety of integration capabilities, including:

The ideal box build assembly solution

Custom cabling
Panel wiring
Modular sub-rack manufacture
Sub-rack installation (backplanes, daughter cards)
Power installation
Power configuration

Heat management
Systems integration
Telecommunications cabinets
Process control and automation
Software loading
Software testing

The ideal box build assembly partner

Lacking build data internally or trapped by your current supplier? ESCATEC can reverse engineer your product and create detailed build and test documentation from scratch using a golden sample as reference.

Going beyond the remit of a typical box build assembly process, ESCATEC’s, design, engineering and manufacturing teams are experienced in the production of complex mechatronics products. These are better described as machines rather than products. They require bespoke configuration; 19" rack sub-systems need to be assembled, and custom hard-wired cabinet assemblies delivered.

In addition to producing and integrating custom PCB assemblies, we can also procure all the necessary parts. These include pneumatics, PLCs, switches, timers, and encoders; as well as plastics, custom metalwork, and machined products.

ESCATEC offer a total manufacturing solution. We take you from product design and supply chain management, through to industrialisation, prototype build and volume production. We establish agile, mechatronics assembly, configuration and test processes, to ensure world class performance levels for quality and OTIF.

ESCATEC's manufacturing capabilities are complemented by enhanced support services for our clients, such as design and development support, test solutions, sophisticated supply chain management, postponement manufacturing and direct-ship outbound logistics.

PCB Assembly

We support customers from the prototype and industrialisation stages, through to the ongoing manufacture of complex, multi-technology PCBAs, in low, medium and high volumes.

Box Build Assembly

We're experts in complex sub-assemblies and finished, tested, products. We offer turnkey electronics, mechatronics, cabinet assembly, system integration & test solutions.

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Mechatronics

ESCATEC offers a wide range of mechatronics solutions and supply chain experience - everything from ‘benchtop’ products through to ‘large format’ electro-mechanical machines.

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Machining

From simple CNC turned components to elaborate CNC milled assemblies, we cater to diverse sectors, including industrial electronic, transportation and medical device manufacturing.

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Test Solutions

A proven method of electronics manufacturing defect detection and prevention, flying probe testing also eliminates the requirement for dedicated fixturing.

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Plastic Injection Moulding

At ESCATEC we use cutting-edge technology and equipment, to ensure that every injection moulding project we undertake meets the highest standards of quality and precision.

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Microelectronics

Our experienced teams design, develop and manufacture high performance LED, laser, and lighting solutions. We ensure micro-optic needs for complex MOEMS products are met and delivered.

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Design & Development

We specialise in electronics, software, mechanical, and system design and development. Following Design for eXcellence (DfX), Design for Manufacture (DFM), and VA/VE best practices, we turn your ideas into market-ready products.

New Product Introduction

Our unmatched NPI support is characterised by lean project management, comprehensive testing, robust supply chain management, and close collaboration with your teams to minimise risks, maximise results, and ensure product quality.

Supply Chain Management

With our established global supplier partnerships, our experienced procurement, SCM, and logistics teams can identify the best sourcing options based on your needs. We supply a vast range of products to various sectors reliably and cost-effectively.

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Prototyping

With our prototyping services, we are with you every step of the way, from schematic design to functional testing and validation. We work with you to refine your designs, creating a high-quality final product ready for mass production.

Post-production

Whether you’re launching a new and improved product iteration or extending the lifecycle of your existing in-market products, our post-production capabilities help to maximise profits and keep you ahead of the competition.

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