A box build is a type of cable assembly, but not an ordinary one. The box build is a unique build that's assembled for a specific purpose. These assemblies are built in accordance with custom drawings and contain a variety of different parts. Being a completely customizable product, this type of assembly can be applied to almost every market type for every kind of application setting.

Box Build Cable Assembly

Designing A Box Build Assembly

When designing a box build, there are quite a few challenges to overcome. These challenges will ultimately vary in complexity based on the overall goal of the box build. Some will be challenging, others will be simple, and once in a while, one will be very complicated. When building these complex assemblies, the ultimate goal is to find a custom manufacturer that will be able to build your product from start to finish, at a cost-effective price. These types of manufacturers are rare and typically charge a premium and a minimum number of assemblies. This can make things confusing, especially when it's your first time ordering.

  

The Sycor team is one of these suppliers. Being a wiring distributor and a cable assembly manufacturer enables our team to purchase parts of the assemblies at a discounted price (lowering the price of the finished product). By using a single manufacturer as a customer, you're now able to coordinate with a single individual rather than multiple organizations. By using multiple vendors, you'll not only have to spend more because of all the shipping required, but you'll also have to allocate additional time to manage the project.

 

 

A reliable supplier of a Box Build assemblies will offer:

  • Prototyping
  • Testing
  • Labelling
  • Product assembly
  • Packaging

 

Box Build requirements:

  • Electrical schematic
  • Drawing of the assembly
  • Bill of materials (BOM)
  • Wire & cable required
  • Test specification
  • A prototype or sample
   

Box Build Cable Assembly Example

What are box build assemblies typically used for?

The box build is a custom product and is used within varying applications. This could be a control unit, power circuits or anything else requiring an electrical box covering. The physical design is quite challenging to plan for as the applications are consistently changing; therefore, designs will need to be customized.

 

The box build is sometimes used for the physical box feature in comparison to traditional or more standardized cable assemblies that are just cables connected, with no exterior protection. The box in these assemblies is quite reliable when protecting from any physical abuse, oil, weather, abrasion, or when the assembly may need to be periodically moved. Unlike the traditional assemblies, the box holds the entire assembly securely together, making changing applications locations quick and safe.

 

One of the more common box build assemblies involves data cable (see image below). The data cable box builds vary quite differently from one another. These assemblies can be very small or so large they can look like a walk-in closet. Data cable assemblies like these are installed in large skyscrapers, condo buildings, hotels, offices, and even larger homes. The larger the building, the larger the build.

Box Build Cable Assembly

  

Box Build Cable Assembly Drawing

The drawing is the most important part of the entire assembly. It's the instructions for what the final product should be able to do, contain, how it's assembled, what additional products are required, and where it will need to be installed.

The manufacturer chosen will be required to make sense of the drawing and find any potential flaws by either double-checking the drawing itself or discovering potential issues in the prototype. This can be a long and tedious process because typically, when one mistake is made, the surrounding parts will often have issues as well. 

If you have ever been tasked with designing one of these builds or tasked with assembling them, you know just how difficult it can be. Different factors can completely throw off your entire design like space-conscious designs, EMI, chemicals, temperature ranges, voltage ratings and more. These factors will determine exactly the maximum and minimum requirements, what approvals will be required, and what hazards your applications may be subject to. 

Box Build Cable Assembly Drawing

Popular Box Build Assembly Requirements:

  • Installation of sub-assemblies
  • Installation components
  • Routing wire harnesses
  • Fabrication of inclosures
  • Product configuration
 

 

Box builds are one of the more complex cable assemblies that exist in the electrical industry today. From manufacturing facilities to office buildings and even outdoor control units, electrical box builds can be used for a wide range of applications in diverse environments. The Sycor team has been building cable assembly box builds for a number of years and has experienced personnel who can help you find a cost-effective solution. Whether you're building a high-temperature assembly or a data assembly, the box build is a reliable construction that can be customized to meet any application's complex needs. For more information on the different types of services Sycor offers, feel free to reach out to one of our sales team members.

 

 

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