Box Build Manufacturing
How we create box build enclosures
We use a variety of materials and enclosure technologies to create custom, durable box build electronics. These enclosure technologies support the integration of high level assemblies into finished box build systems ready to be deployed.
Metalwork solutions enhance the protection and durability of box build assemblies and can accommodate PCB assemblies, cable routing, thermal management and mounting structures while supporting efficient assembly and long-term reliability. Different manufacturing methods can be selected depending on the application, production volumes and enclosure requirements.
Our metalwork capabilities include:
- Aluminium extrusions for lightweight, thermally efficient enclosure structures
- Stamped metal components for high-volume repeat panels
- Sheet metal fabrication using bent, formed, welded or riveted constructions
- CNC-machined metal parts manufactured from solid billet materials
- Cast metal components for complex geometries not achievable through other processes
This allows enclosure structures to be tailored to both the functional and aesthetic requirements of finished electronic products.
Plastic moulding processes are widely used within box build assembly to manufacture protective housings, structural components and enclosure features for electronic systems. Different moulding methods can be selected depending on the application, production volumes and structural requirements.
A range of thermoplastics can be used depending on the environmental and mechanical requirements of the application, including ABS, polycarbonate, polypropylene and nylon.
Injection moulding supports efficient mid- to high-volume production, while foam moulding provides a cost-effective solution for low- to mid-volume structural parts.
Our moulding capabilities include:
- Snap-fit, latching or screw-fix enclosure features
- Ultrasonic welding for permanent enclosure bonding
- A wide range of surface finishes, including textured and soft-touch materials
PCB overmoulding provides an effective encapsulation method for protecting electronic assemblies within demanding operating environments or where devices need to be made tamper-proof.
This process involves moulding protective material directly around electronic components, creating a sealed structure that protects against moisture ingress, contamination and mechanical stress.
Our PCB encapsulation and overmoulding solutions deliver:
- Durable, tamper-resistant protection
- Improved resistance to moisture and environmental exposure
- Integrated protection for cable assemblies and interconnect systems
These capabilities enhance the long-term reliability of electronic products deployed in demanding environments.
Ultrasonic welding is used within box build assembly to permanently join injection moulded plastic components without the need for adhesives or mechanical fasteners. The process uses high-frequency vibration to create strong, consistent bonds between plastic parts while maintaining clean external finishes.
Ultrasonic welding supports the production of seamless, waterproof and tamper-resistant enclosure assemblies for electronic and electromechanical products. It is particularly well suited to applications requiring environmental protection, repeatable assembly quality and secure enclosure construction.
Our ultrasonic welding capabilities support:
- Permanent bonding of injection moulded enclosure components
- Waterproof and dust-resistant enclosure sealing
- Tamper-resistant assembly construction
- Clean external finishes without visible fixings
Key considerations for box build enclosures
Enclosure design plays a critical role in the long-term performance, protection and manufacturability of box build assemblies.
GTK works closely with customers to address their specific requirements, ensuring their enclosures support environmental protection, thermal performance, mechanical reliability and the practical demands of production and servicing.
- Environmental protection against moisture, dust, vibration and temperature exposure
- Thermal management to dissipate heat from embedded electronics
- Mechanical strength to protect PCB assemblies and interconnect systems
- Manufacturing scalability from prototype builds through to volume production
- Serviceability and access where maintenance or upgrades may be required
These factors influence the enclosure materials, encapsulation techniques and moulding processes used during system integration.
Integrated manufacturing services that benefit your box build products
Box build manufacturing is a key stage within GTK’s integrated manufacturing services approach. Instead of managing multiple suppliers, you gain a coordinated manufacturing process that spans your entire product development.
GTK supports your box build programme while connecting it seamlessly to our wider capabilities:
- Cable assemblies manufactured in-house improve consistency and reduce external dependencies
- Display and embedded integration ensures system compatibility from the outset
- High level assembly expertise supports complex sub-assemblies feeding into final builds
- Full system build capability enables turnkey manufacturing where required
- Coordinated global supply leverages the strength of GTK, RDS and Volex facilities
This integrated model helps you reduce total cost of ownership, streamline logistics and maintain design continuity across product families.
Engineering support for your box build solutions
GTK’s engineering teams work with you early to ensure your box build assemblies are designed for manufacturability, reliability and long-term scalability.
Through collaborative engineering and DFM methodologies, we help refine your product before production begins.
By engaging with us early, we can deliver:
- Design optimisation that reduces assembly complexity and production costs
- Early identification of manufacturability risks, avoiding delays later in the programme
- Material and component recommendations aligned with performance and availability
- Improved product consistency through documented assembly processes
- Future-proofed designs that support revisions and lifecycle management
Box build quality, compliance and testing
Quality and compliance are embedded throughout GTK’s box build manufacturing processes. Every assembly is produced within controlled environments and validated through structured inspection and testing protocols.
Our quality approach gives you:
- Confidence in product reliability through comprehensive inspection and validation
- Compliance with relevant industry standards, reducing regulatory risk
- Traceability across components and assemblies for full production transparency
- Repeatable manufacturing processes that support consistent output
- Dedicated quality oversight aligned with your programme requirements
Typical applications for box build solutions
GTK's box build manufacturing supports OEMs requiring complete, market-ready products across regulated and performance-critical sectors.
Some of the applications that we have manufactured for include:
- Industrial automation - fully configured control panels and HMI systems
- Medical equipment - compliant, traceable diagnostic systems
- Off-highway systems - ruggedised assemblies configured and labelled
- Security - integrated surveillance platforms prepared for rapid field rollout
- Energy monitoring - complete systems assembled, tested and packaged
- Consumer - branded, presentation-ready electronic products for distribution
Box build manufacturing FAQs
If you still have a question, check to see if we've answered it here. If not, get in touch with us and we can discuss your box build questions and requirements.