At Protronix EMS, we offer more than just PCB manufacturing. We provide comprehensive box build and electro-mechanical assembly services from our Luton facility.
Whether you require simple enclosure integration or complex cabinet builds with intricate wiring, we deliver finished products ready for your end-user.
Our dedicated mechanical assembly department acts as an extension of your production line, allowing you to consolidate your supply chain. One purchase order covers the PCB, the mechanical parts, the assembly, and the final test.
Our Box Build Capabilities
We support a diverse range of products, from handheld IoT devices to ruggedised industrial control units.
Enclosure Integration
We integrate PCBAs into free-issue or procured enclosures, handling all necessary mechanical modifications.
- Plastic Injection Mouldings: Precision fitting of light-pipes, keypads, and screens.
- Metal Fabrications: Rugged assembly for extruded aluminium or sheet metal chassis.
- Hardware installation: Heat-sinking, stand-offs, and Din-rail mounting systems.
Cable & Wire Harnessing
A box build is only as reliable as its connections. Our technicians are skilled in cable management and loom production.
- Need dedicated cable assembly services? We manufacture custom looms and cable assemblies.
- Custom cable assembly and crimping.
- Ribbon cable installation.
- Complex routing for high-density units to ensure airflow and accessibility.
Potting & Encapsulation
For products destined for harsh environments, we provide in-house potting services. We utilise a range of epoxy and polyurethane resins to protect your electronics from moisture, vibration, and thermal shock.
The "Final Mile" of Manufacturing
We transform a bare circuit board into a saleable product.
1. Firmware & Configuration
We don’t just build the hardware; we wake it up. We handle firmware flashing, software serialisation, and MAC address configuration, ensuring your device is digitally unique and ready to connect.
2. Functional Testing
Beyond standard electrical testing, we perform “real world” functional verification. Using custom test rigs (supplied by you or developed by us), we verify buttons, displays, input/output ports, and safety interlocks.
3. Packaging & Logistics
We can package your product in retail-ready boxes, including user manuals and accessories. We also offer direct fulfilment options, shipping finished goods directly to your distribution hub or end customer.
Box Build Specifications
| Service | Capability |
|---|---|
| Enclosure Types | Plastic, Metal (Aluminium/Steel), Die-cast, Custom |
| Interconnects | Custom Looms, Ribbon Cables, Connectors |
| Protection | Conformal Coating, Potting (Epoxy/Polyurethane) |
| Testing | Functional Test, PAT Testing, Earth Bond Test |
| Configuration | Firmware Flashing, Serialisation, Label Printing |
| Packaging | Retail Packaging, Bulk Industrial, Custom Foam |
| Sourcing | Full Turnkey or Free-Issue Kits |
Why Outsource Mechanical Assembly?
Many OEMs struggle with the transition from PCB to Product. Managing metalwork suppliers, plastic moulders, and cable assembly takes time and floor space.
By partnering with Protronix for the full build, you benefit from:
- Single Point of Accountability: If a cable doesn’t fit the PCB connector, we resolve it. You don’t get stuck in the middle of two blaming suppliers.
- Reduced Inventory: You don’t need to stock enclosures, screws, and packaging. We manage the BOM and deliver on a schedule that suits you.
- Skilled Labour: Our mechanical assembly team is trained in torque settings, ESD safety, and quality inspection, ensuring consistent build quality across every unit.
Let's Build Your Product
From a simple sub-assembly to a complete turnkey box build, we have the space and the skills to deliver. Contact us to discuss your mechanical requirements.
Having worked with a new customer through their prototype phase, following product launch, we built initial small batches to satisfy pilot orders. As the customer scaled, we scaled production to meet their demands.
Hundreds of units turned into thousands and then tens of thousands of units, culminating in a total of approx. 250,000 units being produced, at a peak production rate of 5000 units per week, over a number of months.
PCB assembly, both SMT and THT, programming, test, configuration, final assembly, barcoding and packaging, all completed in house.
“The success and growth of our product would not have been achievable without the quality, service and flexibility we received from Protronix EMS.”
Founder and CEO, IoT Company
If you’ve got a product challenge, get in touch today, or email us your requirements to [email protected].