Tag Archives: PCB Assembly prototype service

Why Running a Trial Run First is Important in PCB Assembly

Do you have a new PCB idea that you’re excited to bring to life? Once your design is finalized and ready for production, it’s tempting to jump straight into a large manufacturing order—especially if you believe the product will sell quickly. But before committing to thousands of units, there’s a far more important question to ask: Will the PCB actually work the way you expect once produced in large quantities?

This is exactly why PCB Assembly strongly recommends performing a trial run before entering mass production. A trial run ensures that your design functions properly, that the build process is stable, and that potential problems are identified early—before they become costly and time-consuming.

What Is a Trial Run in PCB Manufacturing?

A trial run, also known as a pilot run or pre-production build, is essentially a mini mass-production cycle. Instead of producing all 6,000 units immediately, the trial run starts with a much smaller batch, typically around 200 units.

If that initial batch performs well, the order is scaled up to 1,000 units, allowing the engineering and manufacturing teams to:

  • Verify component integrity

  • Validate soldering processes

  • Confirm assembly consistency

  • Identify design or manufacturing flaws

  • Test the product under realistic conditions

Only after the 200- and 1,000-unit runs are successful do we move forward with the full order—such as the complete 6,000-piece production you originally planned.

This method reduces financial risk and ensures that your PCB performs flawlessly before mass production begins.

Why You Should Never Skip the Trial Run

Electronic circuit boardUnfortunately, many companies—especially those importing parts or outsourcing overseas—skip the trial run because they are pressed for time or eager to deliver products to their customers. However, bypassing this stage can result in:

  • Costly redesigns

  • Wasted materials

  • Delayed shipments

  • Failed PCBs

  • Customer dissatisfaction

  • Damage to your brand

A trial run acts as a quality gate, ensuring that your idea translates into a stable, functional, and manufacturable product. It provides the opportunity to confirm that the production line is operating correctly, that the PCB layout translates properly, and that the assembly team can reproduce your design consistently.

Trial Runs Protect Your Investment

Producing thousands of PCBs without first validating the process is a major financial risk. A trial run prevents:

  • Large-scale defects

  • Incorrect component placement

  • Soldering issues

  • Tolerance mismatches

  • Unforeseen board failures

Catching these issues early can save you tens of thousands of dollars and prevent product launch delays.

Start Smart—Test Before You Scale

Whether you’re launching your first PCB design or preparing to scale an existing one, a trial run is one of the most important early steps in the manufacturing process. PCB Assembly is here to guide you through each phase—from prototype to pilot run to full production—ensuring your product works the way it should.

Before you invest in mass production, invest in certainty. Contact us today to schedule your trial run and protect your next big product.

Contact Us Today!!

Box Build Assembly

Box Build vs. PCB Assembly

What’s the Difference and When Do You Need Both?

When it comes to producing electronic devices, PCB assembly and box build are two essential processes that play different but complementary roles in bringing products to life. While many people are familiar with PCB assembly — where components are mounted on a printed circuit board — box build assembly takes it a step further by creating the finished product that’s ready for market.

If you’re wondering what separates a box build from PCB assembly, and when you need both services, this guide will break it down in simple terms.

What Is PCB Assembly?

PCB assembly (Printed Circuit Board Assembly) is the process of placing and soldering electronic components like resistors, capacitors, ICs, and connectors onto a bare circuit board. This process can involve surface mount technology (SMT), through-hole technology, or a combination of both.

In short, PCB assembly focuses on the brain of the device — the electronic board that powers everything.

Key steps in PCB assembly include:

  • Solder paste application
  • Pick and place of components
  • Reflow soldering or wave soldering
  • Inspection and testing

PCB assembly is essential for any electronic device but does not complete the final product — that’s where box build comes in.

What Is a Box Build?

Box BuildA box build (also known as system integration or electronic box build assembly) involves assembling all the necessary components — including the PCB — into a finished, fully functional product.

Think of box build as the final stage of electronic manufacturing. Once your PCB is assembled, tested, and functioning, box build assembly packages everything into its enclosure, adds wiring, and includes other mechanical and electrical parts.

Key elements of box build assembly include:

  • Enclosure assembly (metal, plastic, custom housing)
  • Mounting of PCBs, displays, switches, and other modules
  • Wiring and cable harness assembly
  • Installing connectors, power supplies, fans, and other accessories
  • Full system testing and verification

For more about box build services, check out https://boardassembly.com/box-builds/.

Box Build vs. PCB Assembly: What’s the Difference?

Feature PCB Assembly Box Build Assembly
Focus Assembling components on a circuit board Assembling final product including PCB
Includes Only the electronic board and components PCB + wiring, housing, connectors, and more
End Result A working circuit board Fully assembled, ready-to-use product
Additional Work No enclosures, no system integration Full system integration, packaging, labeling
Testing PCB-level electrical tests System-level testing to verify total function

When Do You Need Both PCB Assembly and Box Build?

Most finished electronic products require both PCB assembly and box build to be market-ready. If you are producing any of the following, you will likely need both services:

  • Consumer electronics (smart devices, home gadgets)
  • Medical devices (monitors, diagnostic tools)
  • Industrial equipment (control panels, automation systems)
  • Telecommunication devices (routers, communication boxes)
  • IoT devices (smart sensors, connected devices)

Here’s when both services are essential:

  1. Product Readiness: If you want a product ready for sale or shipment — not just a circuit board — you need box build after PCB assembly.
  2. Complex Wiring Needs: If your device requires wiring, cable assemblies, and mechanical enclosures, a box build is necessary to integrate these parts.
  3. Testing & Compliance: Final system-level testing (functional tests, safety tests) happens during box build, ensuring the product works as intended before it reaches customers.

Why Work with a Partner Who Offers Both?

Choosing a manufacturing partner like Board Assembly that offers both PCB assembly and box build services can save time, reduce costs, and improve quality control. Here’s why:

  • Streamlined communication: Manage one relationship instead of coordinating between separate vendors.
  • Faster turnaround: PCB and box build handled under one roof means fewer delays.
  • Lower costs: Combined services often mean better pricing on components and assembly.
  • Better quality assurance: One team ensures your product is built and tested according to your specifications.

Box BuildWhile PCB assembly focuses on building the electronic board, box build assembly brings all components together into a finished, functional product. Most companies need both services to ensure their devices are ready for customers.

If you’re looking for a reliable partner for box builds and PCB assembly, Board Assembly has the expertise to handle your project from start to finish — simplifying your production process and delivering high-quality results.

Contact Us to Learn More

➡️ Ready to start your next electronic box build or PCB assembly project? Contact Board Assembly today to discuss how we can help streamline your manufacturing and bring your product to life!