After SMT and THT assembly, the PCB (printed circuit board) becomes a PCBA (printed circuit board assembly), a modular or functional board that can be further assembled with other boards to form a complete system. Is PCB assembly the end of electronics manufacturing services from a turnkey PCB assembly manufacturer like PCBONLINE? NO. There are value-added services in the post-assembly stage.
What are the value-added services for PCBA? PCBA value-added services from PCBONLINE include conformal coating, IC programming, burn-in aging, enclosures, and box-build assembly.
Finished device assembly means we provide the enclosure, install the PCBA within the enclosure, and connect the cable harness. We then conduct an application simulation test, label and package the device, and prepare it for market launch, ready for sale and use.
What is Needed for Finished Device Assembly
PCBA is definitely required for finished device assembly. Beyond PCBA manufacturing, PCBONLINE sources the cable harness and mechanical hardware and collaborates with the top 3 enclosure manufacturers in China to supply the custom enclosures used for finished device assembly.
- PCBA: A functional electronics board assembled with all the required components listed in the BOM (bill of materials).
- Custom enclosures: Whether it’s plastic injection molding, CNC-machined metal, or ruggedized shells, we ensure the PCBA fits perfectly and is protected from the environment.
- Cable harnesses: Internal wiring and external connectors are precision-manufactured to ensure signal integrity and durability.
- Mechanical hardware: Brackets, standoffs, screws, nuts, and bolts to secure the cable harness to the PCBA and the enclosure, and encase the enclosure from water and dust.
Mechanical Integration of Finished Device Assembly
The physical installation of the PCBA into the enclosure is where precision matters most. Our assembly teams handle thermal management, ESD-safe environment, fastening, and sealing.
- Thermal management: Proper application of thermal pads or heat sinks to ensure the device doesn't overheat.
- ESD-safe environment: All assembly occurs in Electrostatic Discharge (ESD) protected areas to prevent latent damage to sensitive components.
- Fastening and sealing: Precise torque control for screws and professional sealing to meet IP (Ingress Protection) ratings if required.
FAE & Simulation of Finished Device Assembly
PCBONLINE offers FAE (Field Application Engineering) application simulation tests for the finished devices. While standard functional tests (FCT) check if the PCBA works, the application simulation test checks if the device survives and performs in its specific real-world environment.
Our FAE team acts as technical consultants between the design and the manufacturing floor. Our Field Application Engineering (FAE) support includes:
- Hardware-software calibration: Ensuring the firmware is correctly flashed and that the hardware responses match the software logic under various inputs.
- Troubleshooting: Identifying tricky issues that only appear after the PCBA is housed in its enclosure, such as signal interference caused by the metal casing or connector tension issues.
- Design feedback: If a device fails during simulation, FAEs provide a failure analysis report to help you adjust the design for better yield in mass production.
The Application Simulation Test involves placing the fully assembled device into a setup that mimics its end-use environment. We don't just test the electrical signals but also the product's behavior as a whole. Our environmental simulation includes:
- Thermal stress: Testing the finished device in high or low temperatures (part of a 12–168 hour burn-in aging test) to ensure the enclosure doesn't trap too much heat and cause component failure.
- Humidity/salt spray: For outdoor or industrial devices, we simulate corrosive or damp environments to check the integrity of the enclosure seals and the durability of the assembly.
- Signal integrity: Checking for EMI (Electromagnetic Interference) now that the PCBA is inside a box and connected to external cable harnesses.
- Mechanical stress: Simulating the physical forces the device will encounter, such as vibration for automotive use or button-press cycles for consumer electronics.
- Power supply simulation: Testing the device against voltage fluctuations or dirty power inputs to ensure the internal power management can handle electrical grids.
Labeling and Packaging in Finished Device Assembly
The final Value Add is making the product ready for immediate sale and use. Our turnkey PCB assembly factory handles the tasks, including labeling and packaging.
Labeling: We apply regulatory labels (CE, FCC, RoHS), serial numbers, and branding stickers with precision.
Packaging: From custom-printed retail boxes to protective shipping inserts, we package the device so it is ready to be shipped directly to distributors or end-users.
Partner with PCBONLINE for EMS PCB Assembly
PCBONLINE is a turnkey PCBA manufacturer providing EMS PCB assembly, including finished device assembly. We provide all the electronics manufacturing and materials used for our PCB box-build assembly services, including the PCB enclosures.
Our EMS PCBA manufacturing services offer:
- Complete procurement: We source and customize enclosures, cables, and accessories from reliable suppliers.
- Engineering support: We check enclosure and accessory designs for compatibility with your PCBA and can suggest design changes.
- Free DFM/DFT: We provide free Design for Manufacturability (DFM) and Design for Testability (DFT) checks to ensure that designs are optimized for a smooth production process.
- Special capabilities: IPX8 waterproof enclosures and encapsulation for rugged outdoor devices.
- Quality assurance: IPC-A-610 Class 3, automotive-grade or industrial-grade inspection standards.
- Turnkey delivery: From PCB fabrication to final product packaging and shipping.
- Testing and value-added services: Offering a range of quality assurance services, including X-ray inspection for hidden-joint PCBAs, first-article inspection, PCBA functional testing (FCT), IC programming, burn-in test, PCBA coating, enclosures, and box-build assembly.
Founded in 2005, our two advanced PCB manufacturing bases are in Jiangsu and Jiangxi Provinces, and our turnkey PCB assembly factory is in Shenzhen. Besides, we have an R&D team and a global supply network. We also maintain strategic cooperation with the top 3 fixture and enclosure factories in China to manufacture the custom PCBA fixtures and device enclosures.
PCBONLINE manufactures, assembles, and tests PCBs and PCBAs to box builds as a source factory manufacturer under one roof, from prototypes to bulky production, saving costs and time for you.
We keep strategic cooperation with the top 3 enclosure manufacturers in China to manufacture custom device enclosures.
We can design the PCB enclosure to match your PCB. Besides, we can help create user manuals, installation guides, and compliance labels.
Our high-quality PCBA contract manufacturing is certified with ISO 9001:2015, ISO 14001:2015, IATF 16949:2016, RoHS, REACH, UL, and IPC-A-610 Class 2/3.
Our one-on-one free and professional DFM helps you debug and improve design, to ensure the manufacturability, cost-effectiveness, and final device success.
Whether you need EMS PCB assembly to build consumer IoT devices, creative electronic products, automotive/medical-grade systems, etc, with 20 years of PCBA manufacturing and box build experience, we ensure that both electronics performance and final product presentation meet the highest standards. To get a quote for your EMS PCB assembly project, email us at info@pcbonline.com.
Conclusion
By choosing a partner that understands the nuances of finished device assembly, you turn a complex manufacturing puzzle into a streamlined experience. Contact us to build EMS PCBA or box-builds to deliver your products to success.
