Box Build Assembly - Jayshree Instruments

Everything from enclosure to end-user. Under one roof.

Our box build capability goes far beyond putting a PCB in a box. We manage the entire electromechanical BOM — integrating PCBs, wire harnesses, mechanical components, software, and packaging into a single, fully tested finished product.

Electromechanical integration

Cable routing & management

Potting & conformal coating

Firmware loading & software configuration

Final packaging & kitting

Traceability & serialisation

Electromechanical integration

Seamless integration of PCBs, wire harnesses, displays, switches, fans, and mechanical components assembled with torque-controlled fastening and full alignment checks.

Torque-controlled fastening
ESD-safe PCB mounting
Sub-assembly integration
Thermal paste and gasket application.

Cable routing & management

Industrial-grade cable dressing, labelling, and routing for clean airflow, serviceability, and compliance using zip ties, clips, conduit, and strain relief to IPC standards.

Clean routing for airflow and serviceability
Strain relief and connector mating
Cable identification and labelling
Integrated with our wire harness capability

Potting & conformal coating

Automated potting and conformal coating for IP67/IP68 environmental sealing and protecting assemblies from moisture, dust, vibration, and chemical exposure in harsh environments.

Potting for full encapsulation
Conformal coating for PCB protection
IP67/IP68 rating verified by test
Suitable for outdoor and industrial use

Firmware loading & software configuration

In-house firmware flashing, MAC address serialisation, and customer-specific configuration loading every unit leaves our floor with the correct software version verified and logged.

Firmware flashing and verification
MAC address and serialisation
Market-specific configuration loading
Calibration data upload

Final packaging & kitting

Retail-ready packaging with custom foam inserts, user manuals, accessories, and safety labelling, every unit packed and kitted to your exact specification, ready for end-user delivery.

Custom foam and packaging design
User manual and accessory inclusion
Safety labelling and compliance marking
Drop-shipping direct to end customer

Traceability & serialisation

Serial number tracking for every board and major sub-assembly in the unit with full build records maintained throughout, supporting warranty claims, field investigations, and regulatory audits.

Unit-level serial number tracking
Sub-assembly genealogy records
Full build documentation per unit
Regulatory audit-ready records

Everything from enclosure to end-user. Under one roof.

Electromechanical integration

Seamless integration of PCBs, wire harnesses, displays, switches, fans, and mechanical components assembled with torque-controlled fastening and full alignment checks.

Torque-controlled fastening
ESD-safe PCB mounting
Sub-assembly integration
Thermal paste and gasket application.

Cable routing & management

Industrial-grade cable dressing, labelling, and routing for clean airflow, serviceability, and compliance using zip ties, clips, conduit, and strain relief to IPC standards.

Clean routing for airflow and serviceability
Strain relief and connector mating
Cable identification and labelling
Integrated with our wire harness capability

Potting & conformal coating

Automated potting and conformal coating for IP67/IP68 environmental sealing and protecting assemblies from moisture, dust, vibration, and chemical exposure in harsh environments.

Potting for full encapsulation
Conformal coating for PCB protection
IP67/IP68 rating verified by test
Suitable for outdoor and industrial use

Firmware loading & software configuration

In-house firmware flashing, MAC address serialisation, and customer-specific configuration loading every unit leaves our floor with the correct software version verified and logged.

Firmware flashing and verification
MAC address and serialisation
Market-specific configuration loading
Calibration data upload

Final packaging & kitting

Retail-ready packaging with custom foam inserts, user manuals, accessories, and safety labelling, every unit packed and kitted to your exact specification, ready for end-user delivery.

Custom foam and packaging design
User manual and accessory inclusion
Safety labelling and compliance marking
Drop-shipping direct to end customer

Traceability & serialisation

Serial number tracking for every board and major sub-assembly in the unit with full build records maintained throughout, supporting warranty claims, field investigations, and regulatory audits.

Unit-level serial number tracking
Sub-assembly genealogy records
Full build documentation per unit
Regulatory audit-ready records

Seven sequential steps. Quality gates at every one.

Every box build follows a structured, documented assembly workflow with defined inputs, outputs, and quality checks at each stage so issues are caught before they progress.

1 Sub-assembly preparation
2 PCB integration
3 Cable routing & harness integration
4 Potting, coating & sealing
5 Firmware loading & system configuration
6 Final QA & safety testing
7 Pack, kit & ship

Sub-assembly preparation

Pre-forming cables, mounting standoffs, heat-staking plastics, and preparing all sub-assemblies before integration begins ensuring every component is ready and verified before it enters the build sequence.

PCB integration

Precise board mounting with ESD controls, torque-controlled fastening, and alignment checks ensuring every PCB is correctly positioned, secured, and protected before further integration.

Cable routing & harness integration

Clean cable routing with zip ties, clips, and strain relief following exact routing drawings to ensure airflow, serviceability, and compliance with IPC workmanship standards throughout the enclosure.

Potting, coating & sealing

Conformal coating, potting, and gasket installation applied where specified with IP rating verified by vacuum or pressure decay testing after sealing to confirm environmental protection.

Firmware loading & system configuration

Firmware flashing, MAC address serialisation, and customer-specific configuration loading with version verification logged against the unit serial number before functional testing begins.

Final QA & safety testing

Cosmetic checks, gap verification, safety labelling, HiPot testing, and functional test sign-off, every unit released only after passing the full quality gate and being cleared by a trained QA inspector.

Pack, kit & ship

Custom foam inserts, user manuals, accessory kitting, and safety labelling packed to your exact specification and either despatched to your warehouse or drop-shipped direct to your end customer.

Box build expertise across industries where finished product quality is non-negotiable.

Renewable energy

Environmental sealing, thermal management, field-ready finished assemblies

Medical diagnostic devices

Cleanroom-compatible assembly, full traceability, ISO 13485 flow support

Telecom rack units

High-density integration, cable management, 19-inch rack-mount assembly

Industrial controllers & PLCs

Ruggedised enclosures, torque-critical assembly, continuous-operation reliability

IoT gateways & sensors

Firmware loading, MAC serialisation, compact enclosure integration

EV charging stations

IP67/68 sealed enclosures, HiPot safety testing, outdoor-rated assembly

Every unit tested. Every shipment signed off.

Nothing leaves our facility without passing a comprehensive testing protocol covering electrical safety, functional performance, environmental sealing, and software verification.

Functional test (FCT)

Automated test rigs exercising all inputs, outputs, and communication ports simulating real-world operating conditions to verify full system functionality before despatch.

HiPot & ground bond testing

High-potential electrical safety testing for mains-powered devices verifying insulation integrity and ground bond resistance to ensure user safety in the field.

IP rating verification

Vacuum or pressure decay testing to verify IP67/IP68 environmental sealing confirming dust and water protection on every sealed enclosure before it leaves the line.

Software & firmware verification

Version confirmation, functional validation, and configuration verification logged against each unit's serial number for complete traceability.

Burn-in testing

Operating units at elevated temperatures under load to screen for infant mortality failures ensuring only field-proven units ship to your customers.

Cosmetic & final visual inspection

Gap verification, label placement, cosmetic quality check, and packaging inspection, every unit reviewed by a trained QA inspector before release.

Every unit tested. Every shipment signed off.

Nothing leaves our facility without passing a comprehensive testing protocol covering electrical safety, functional performance, environmental sealing, and software verification.

Functional test (FCT)

Automated test rigs exercising all inputs, outputs, and communication ports simulating real-world operating conditions to verify full system functionality before despatch.

HiPot & ground bond testing

High-potential electrical safety testing for mains-powered devices verifying insulation integrity and ground bond resistance to ensure user safety in the field.

IP rating verification

Vacuum or pressure decay testing to verify IP67/IP68 environmental sealing confirming dust and water protection on every sealed enclosure before it leaves the line.

Software & firmware verification

Version confirmation, functional validation, and configuration verification logged against each unit's serial number for complete traceability.

Burn-in testing

Operating units at elevated temperatures under load to screen for infant mortality failures ensuring only field-proven units ship to your customers.

Cosmetic & final visual inspection

Gap verification, label placement, cosmetic quality check, and packaging inspection, every unit reviewed by a trained QA inspector before release.

One roof. One team. One finished product.

Box build is where everything comes together and where handoffs between vendors create the most risk. Here's why the
teams who can't afford that risk choose us.

PCB assembly + wire harness + box build - all in house

Every component of your finished product is built under one roof by one team. No handoffs between PCB house, harness supplier, and box builder – no gaps in accountability.

Firmware loading included

We flash and verify your firmware in-house so your product leaves our facility tested, configured, and ready for the end user, not just assembled.

Drop-ship direct to your end customer

We can fulfil orders directly from our facility reducing your logistics overhead, cutting lead time to end-user, and simplifying your supply chain significantly.

Scalable from prototype to mass production

From a 10-unit engineering prototype to a 10,000-unit production run – the same team, the same quality systems, and the same traceability at every volume.

99.2% on-time delivery

Reliable programme management, real-time production monitoring, and a supply chain built for continuity so your product ships when it’s supposed to.

25+ years of electromechanical integration experience

Decades of cross-industry box build experience means your programme benefits from lessons already learned reducing risk at every stage of integration.