Box Build Assembly Services for Complex Systems
PEKO offers turnkey box build assembly services tailored for OEMs manufacturing complex and highly regulated electromechanical systems. Our expertise spans the entire lifecycle—from mechanical fabrication to full systems integration—delivering fully functional, ready-to-use box build solutions.
What is a Box Build Assembly?
Box build assembly is the process of integrating mechanical, electrical, and electronic components into a complete, self-contained system housed within an enclosure—often referred to as a “box.” This step goes well beyond simply assembling parts; it’s a highly coordinated, multi-disciplinary process that demands mechanical precision, electrical expertise, software integration, and rigorous quality control. A typical box build may include:
- Custom enclosures fabricated from sheet metal or machined materials
- Mechanical components such as chassis, brackets, hinges, fasteners, and internal supports
- Electrical elements like circuit boards, wiring, cable assemblies, power supplies, sensors, and relays
- User interface components including buttons, switches, displays, touchscreens, and I/O connectors
- Pre-assembled modules such as motion controllers, communication units, or power management subsystems
- Embedded software and firmware to enable intelligent functionality and system control
The result is a fully integrated product that’s ready to perform its intended function—whether it’s controlling industrial automation equipment, powering advanced medical devices, or supporting mission-critical defense systems.
How It Fits into the Manufacturing Process
Box build assembly isn’t simply an assembly step—it’s a critical phase in the manufacturing of capital equipment and high-performance systems following the production of individual components and subassemblies where all prior work comes together. At this stage, attention to detail is vital—every connection must be reliable, every component must be secured, and every part must function in harmony with the rest of the system. In many cases, box builds represent the final deliverable product that is shipped to the end customer or integrated into a larger system.
PEKO’s Comprehensive Box Build Contract Manufacturing Capabilities
PEKO offers end-to-end box build solutions—all under one roof. Our process spans a wide array of tasks and is tailored to your preferred level of involvement, whether you’re looking for full turnkey support or collaboration at specific stages.
- Design & Engineering Support: Our cross-functional engineering teams work with yours to ensure manufacturability, scalability, and success.
- Refine designs for optimal manufacturability and assembly efficiency (DFMA)
- Full CAD modeling for precision-fit enclosures and custom fixtures/tooling
- Test engineering and plan development, including FMEA and FAI procedures
- Low-volume prototype builds to mature designs before moving to production
- Assistance with process improvement, value engineering, and documentation
- Supply Chain Management: Our logistics and procurement experts ensure component availability and supply chain resilience.
- Strategic sourcing of COTS components and vendor management
- Support for consigned, VMI, Kanban, and JIT inventory management
- Detailed material planning, including blanket orders and long-lead items
- Mechanical Fabrication & Assembly: We manufacture and assemble your physical box build infrastructure—frames, enclosures, brackets, and more.
- On-site machining, sheet metal fabrication, welding, and finishing of mechanical components
- Fabrication of custom enclosures using advanced manufacturing techniques and technologies
- Assembly of frames, internal supports, and other structural elements within the enclosure
- Mounting of mechanical components, like chassis, brackets, and fasteners, to the enclosure
- Electromechanical Integration: We carefully build out the internal system, combining all mechanical and electrical parts into a fully functional unit.
- Enclosure integration with required electronic components and electromechanical subsystems
- Precise cable and wire harnessing, routing, grounding, and signal integrity per IPC standards
- Support for embedded firmware loading, configuration, and programming, if needed
- Controlled ESD-safe handling and assembly environments available for sensitive electronics
- Testing & Quality Assurance: We ensure every unit is verified against performance, safety, and regulatory requirements.
- Rigorous functional and electrical testing and quality control procedures per application needs
- Verification against UL, CE, RoHS, IPC-A-610/620, MIL-STD, and customer-specific protocols
- Complete documentation and traceability of components, assembly steps, and testing results
- Adherence to ISO 9001, ISO 13485, AS9100, and ITAR compliance
- Packaging & Fulfillment: We finalize your box build for seamless delivery—fully packaged, clearly labeled, and ready for deployment or integration.
- Labeling with part numbers, serials, compliance marks, and product tags
- Custom packaging tailored to product dimensions, fragility, and regulatory needs
- Final preparation for shipment, including kitting, manuals, and regulatory documentation
- Direct-to-end-user shipping or integration site delivery with secure logistics coordination
Industries & Applications
PEKO’s box build programs support a wide range of high performance, regulated industries:
- Industrial Equipment – Power distribution units, sensor-integrated control panels, and motion control systems for industrial automation environments.
- Medical Equipment – Precision-assembled electrical enclosures and operator modules for diagnostic tools, imaging systems, and monitoring equipment.
- Defense & Aerospace – Ruggedized, shock- and vibration-resistant enclosures that house mission-critical electronics for aerospace and defense systems.
- Semiconductor & Electronics –Cleanroom-compatible and contamination-sensitive power supply modules, diagnostic boxes, and subsystem enclosures.
- Renewable Energy Systems – Battery management systems, inverter assemblies, and control enclosures used in solar, wind, and energy storage systems.
Why OEMs Trust PEKO for Box Build Assembly
Delivering a successful box build isn’t just about putting parts together—it’s about expertly orchestrating the integration of mechanical, electrical, and software systems into one seamless, high-performing product. It requires deep engineering insight, meticulous execution, and cross-functional coordination to ensure every component works in perfect harmony. This is exactly where PEKO stands out among box build assembly manufacturers.
Expertise with complex, regulated, and high-mix systems- ISO 9001, ISO 13485, AS9100, and ITAR compliant facilities
- Full in-house machining, sheet metal, assembly, wiring, and testing
- Strategic sourcing, inventory control, and long-lead planning
- Custom work cells and trained assemblers for every program
- Scalable capacity: prototype, LRIP, and full-rate production
- Dedicated project engineering & program management
- U.S.-based operations for secure, reliable production
FAQs About PEKO’s Box Build Services:
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Can you handle projects other manufacturers have turned away?
- Yes! We specialize in tackling complex, highly customized box build assembly that other providers may find too difficult or niche. Our experienced engineering and manufacturing teams thrive on challenging projects.
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What level of assembly volume can PEKO support?
- We specialize in low to medium volume production, typically in the low hundreds of units. Our flexible production lines and scalable resources allow us to accommodate small runs, prototypes, and custom builds, while adjusting to seasonal or demand fluctuations.
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Can PEKO help with design and engineering?
- Yes! PEKO provides engineering collaboration and design support to help optimize your product for manufacturability, cost efficiency, and performance. Our services include enclosure design, material selection, layout optimization, detailed CAD drafting, and development of custom tooling and fixtures. We also offer process improvement recommendations, along with test engineering support and documentation preparation to ensure a smooth transition into production.
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Do you handle mechanical fabrication in-house?
- Absolutely. PEKO offers full in-house mechanical fabrication that allows us to produce custom sheet metal enclosures and critical-to-function mechanical components on site. Our capabilities include CNC machining, precision sheet metal fabrication (cutting, forming, bending, rolling), welding, brazing, and surface finishing (powder coating, wet painting, silk screening).
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Can PEKO manage the entire supply chain?
- Yes! PEKO offers full supply chain management, including sourcing, vendor coordination, material planning, and inventory control (VMI, Kanban, JIT). We procure all standard hardware and electronic components—like switches, sensors, relays, and power supplies—through our vetted supply chain partners. We also manage consigned inventory and long-lead items such as PCBAs and ICs to keep your box build on schedule. Custom packaging and logistics are available to support streamlined delivery.
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Who ensures quality and precision of PEKO’s box builds?
- PEKO’s success in box build programs is driven by the strength and versatility of our in-house team. We staff each program based on your build’s specific technical needs—ensuring reliable outcomes from prototype to production.
- Licensed electricians handle complex wiring, terminal block routing, grounding, and testing.
- Manufacturing engineers optimize tooling, fixturing, and overall manufacturability.
- Assembly technicians execute builds with training in mechanical, electrical, and QA tasks.
- Test personnel verify functionality and performance through rigorous system-level testing.
- PEKO’s success in box build programs is driven by the strength and versatility of our in-house team. We staff each program based on your build’s specific technical needs—ensuring reliable outcomes from prototype to production.
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How do I get started with PEKO’s box build services?
- Here’s how you can get started:
- Contact our team with your project details.
- Share your BOM, schematics, testing requirements, and timeline.
- Collaborate with our engineering team to review and optimize the design.
- Receive a detailed proposal and project plan.
- Let us handle the rest—so you can focus on growing your business.
- Here’s how you can get started:
Are PEKO’s Box Build Assembly Services Right for Your Project?
- Do you need electromechanical assemblies that meet strict industry standards?
- Do you need partner to handle complex, high-value systems that others avoid?
- Do you need flexible production for custom, low-to-medium volume builds?
If you answered yes to any of these questions — PEKO may be exactly the box build contract manufacturing partner your team has been searching for. From simple builds to highly engineered electromechanical systems, we customize each program to match the exact needs of your project.