ENCLOSURE & BOX BUILD

Standard PCB assembly ends when the populated and tested circuit board is packaged for shipment. Box build assembly extends far beyond the board level to encompass full electromechanical system integration. At Calpak USA, a box build typically includes mounting one or more assembled PCBAs into an enclosure, routing and terminating internal wire harnesses and cables, installing mechanical components such as fans, power supplies, displays, and switches, loading firmware or software, performing system-level functional testing, and packaging the finished product for end-customer delivery. Box build is essentially the final manufacturing step that transforms individual sub-assemblies into a deployable product. Calpak USA manages box build projects from our Hawthorne, California facility under AS9100 Rev. D quality controls, with full traceability from component level through finished system. This single-source approach eliminates coordination overhead between separate board and system integrators.

Yes. Calpak USA performs comprehensive system-level functional testing on every box build assembly, going beyond the board-level tests conducted during PCB assembly. System-level tests verify that all sub-assemblies, wiring, connectors, and mechanical components work together as an integrated unit. Test scope varies by product and is defined collaboratively with your engineering team. Common system-level tests include power-on sequencing, I/O port verification, communication interface validation (Ethernet, USB, serial, CAN bus), display and indicator verification, thermal performance under load, and safety testing such as hi-pot and ground continuity per UL or IEC standards. Calpak USA develops test procedures and fixtures specific to your product at our Hawthorne, California facility, and all test results are documented with serial-number traceability under our AS9100 Rev. D quality management system. Failed units are segregated, root-caused, and repaired before retest and shipment.

Yes. Calpak USA integrates firmware loading, software installation, and product configuration into the box build assembly workflow at our Hawthorne, California facility. Services include microcontroller and FPGA firmware programming via JTAG, SWD, SPI, or UART interfaces, operating system and application software installation on embedded Linux or Windows platforms, serial number and MAC address provisioning, calibration parameter loading, and configuration file deployment. Calpak USA maintains version-controlled firmware repositories so that each production lot receives the correct software revision as specified by your engineering change order. Programming is performed after PCB assembly and before system-level functional testing to ensure the loaded software is validated in the final product configuration. For ITAR programs, all firmware and software assets are handled under export-controlled data security protocols with access restricted to authorized U.S. persons per our ITAR registration requirements.

Calpak USA works with both custom-fabricated enclosures and commercial off-the-shelf (COTS) enclosures in metal and plastic. Custom enclosures are typically supplied by your sheet metal or injection molding vendor, or Calpak USA can procure them through our qualified fabrication partners to your drawings and specifications. COTS enclosures from manufacturers like Hammond, Bud Industries, or Polycase are sourced through our standard procurement channels. Calpak USA assembles products ranging from small handheld plastic enclosures to large 19-inch rack-mounted chassis, DIN-rail-mounted industrial housings, and sealed IP-rated outdoor enclosures. Our assembly technicians perform all mechanical integration including standoff installation, PCB mounting, panel cutout fitment, gasket seating, and hardware torque verification to documented specifications. All enclosure work is performed at our Hawthorne, California facility under AS9100 Rev. D controls with incoming inspection on all enclosure components before assembly begins.

Calpak USA manages revision control for multi-board box builds through our AS9100 Rev. D configuration management system. Each sub-assembly, including individual PCBAs, wire harnesses, mechanical components, and firmware versions, is tracked by part number and revision level in our MRP system. When your engineering team issues an ECO affecting any sub-assembly, Calpak USA updates the bill of materials, work instructions, and test procedures before the next production lot begins. Serialized traceability links each finished box build to the specific revision and lot code of every internal sub-assembly, so field returns can be traced to exact component and firmware configurations. For products with multiple PCBAs that must maintain revision compatibility, Calpak USA flags interboard dependency rules in the production documentation. Our Hawthorne, California production team performs a configuration audit on the first unit of each lot to verify that all sub-assembly revisions match the current released BOM before proceeding with full-lot assembly.

Yes. Calpak USA offers full end-of-line services including custom packaging, product labeling, serialization, and direct drop-ship delivery to your customers or distribution centers. Packaging options range from anti-static bags and foam-lined boxes for sensitive electronics to retail-ready packaging with printed inserts, barcoded labels, and branded outer cartons. Calpak USA applies product labels with serial numbers, UPC codes, regulatory marks (UL, CE, FCC), and customer-specified branding. Serialization data is captured in our production database and provided in electronic format for your asset tracking systems. For drop-ship programs, Calpak USA ships finished products directly to your end customers or regional warehouses using your preferred carriers and shipping accounts, with packing slips formatted to your specifications. All packaging and labeling services are managed from our Hawthorne, California facility under ISO 9001 document control to ensure label accuracy, correct packaging configurations, and consistent presentation across every shipment.