Electro-mechanical assembly and box build

Overview

System integration, done in-house

Electro-mechanical assembly, also called box build, is where separate parts become one product. We take your electronic components, wiring and mechanical hardware and integrate them into a complete, working system.

What makes Star Precision different is that we also fabricate the enclosure and populate the boards. So instead of shipping metal to one vendor and boards to another, you get the enclosure, the PCBA and the wire harness assembled, tested and troubleshot by a single team. Our department is ESD-safe with IPC certified inspectors on the floor.

Box build capabilities

Everything needed to turn components into a finished, tested system, broken down into the three things a box build actually requires.

System integration

Custom box builds combine electronic components, boards and mechanical hardware into a full working system, assembled by the same team that fabricated the enclosure and populated the boards, so nothing is guessed at across a handoff.

Wiring and harness integration

Cable and wire harnesses are routed, dressed and connected inside the build to link boards and hardware, built to IPC/WHMA-A-620 by the same department that will install them, not shipped in from an outside harness house.

Testing and troubleshooting

Comprehensive product testing verifies the finished system against your requirements, and any fault found is diagnosed and fixed on the same floor where the unit was built, not returned for a separate repair cycle.

Enclosure, boards and harness as one

Because fabrication, machining and electronics share our two Houston facilities, we build the whole product, not just one layer of it, for customers nationwide.

• Fabricated enclosureLaser cut, formed and welded metal built in-house.
• Populated boardsPCBA from our ESD-safe electronics department.
• Cable and wire harnessCustom harnesses routed and connected in the build.
• Full functional testThe complete unit is verified before it ships.

Electro-mechanical assembly specifications

Real, in-house box build capacity with quality control built into every stage, from the fabricated enclosure through the populated board to the finished, tested unit. Bring us a challenging build and we will tell you exactly how we would integrate it.

Our box build process

Every job follows the same controlled path, from design review to final functional test, so the finished system arrives complete, tested and ready to use whether you order one unit or a full production run.

1. Design and DFM reviewWe review your product, drawings and bill of materials, flag anything that would slow the build, and quote the complete system as one package.
2. Fabricate the enclosureSheet metal and machined parts for the enclosure are laser cut, formed, welded and machined in-house, by the same team that will assemble the final unit.
3. Populate the boardsOur ESD-safe electronics department populates and tests the PCBAs for the system on the same MES-tracked line used for any standalone board order.
4. Build the wiringCable and wire harnesses are cut, crimped, soldered and tested to IPC/WHMA-A-620, ready for integration.
5. Integrate and assembleBoards, harnesses and hardware are assembled into the enclosure as one unit, with labeling and serialization applied as needed.
6. Test, troubleshoot and shipThe finished system is functionally tested against your requirements, any issues resolved on the same floor where it was built, then packaged and shipped.

Industries we serve

Star Precision integrates complete, tested products for demanding Texas and national manufacturers, including the regulated and technical sectors below, where certified ESD-safe assembly matters as much as the finished system:

• Commercial lightingWe integrate driver boards, wiring and housings into complete lighting fixtures.
• Defense & militaryWe integrate ruggedized enclosures and electronics to demanding defense specifications.
• Electronics, data & telecomWe integrate racks, cabinets and complete box builds for data infrastructure.
• Industrial & OEMWe integrate frames, boards and wiring into complete equipment for OEM manufacturers.
• Medical & scientificWe integrate instrument frames and electronics into complete device assemblies.
• Oil, gas & energyWe integrate control panels and enclosures built for harsh service.

What to expect when you work with us

Working with a box build partner should be straightforward. From the first file you send to the finished system arriving on your dock, here is what you can count on from our team.

• Send drawings and a BOMSend drawings, a bill of materials and CAD data for the enclosure and boards, and we will scope the whole build.
• Fast, honest quotesYou get one quote for the complete integration, not separate figures to assemble yourself.
• One point of contactOne team owns your job from fabrication through electronics and final test, all under one roof.
• NDAs on requestWe sign NDAs on request, so your system design stays fully confidential.
• On-time deliveryYou get dependable, on-time delivery from our Texas shop, not an overseas queue.

Electro-Mechanical Assembly FAQs

Quick answers about our box build services. Company-wide questions are covered in the FAQs at the bottom of the page.

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