Powering Innovation with End-to-End Box Build Solutions
Box Build
Meeting the Rising Demand for Integrated Solutions
As product designs grow more compact, functional and customised, OEMs are increasingly seeking EMS partners that can handle full system integration. Box build – or system-level assembly – has become a critical differentiator, especially for low- to medium-volume, high-mix applications across industries such as medical, industrial automation, clean tech and semiconductor equipment.
Our Capabilities
The Art of Box Build Assembly
System Assembly
Our system assembly solutions bring together mechanical, electrical and electronic components into a fully integrated, complete and reliable product.
System-Level Test
Through DFT-driven design, we develop test systems that deliver maximum coverage and meet customer-defined specifications.
Cleanroom Assembly
Assembly is conducted on ESD-compliant floors, with the added capability of NEBB-certified ISO 7 and ISO 8 cleanroom environments for processes requiring elevated cleanliness standards.
What We Do
End-to-End Box Build Assemblies
At Flexi Versa Group, we offer box build solutions that encompass everything from PCB integration and wiring to enclosure assembly, functional testing and final packaging. Our expertise spans a wide range of industries, including medical, consumer electronics and industrial automation, ensuring that every product meets the highest standards of quality, reliability and efficiency. With a focus on precision engineering and streamlined manufacturing, we optimise production processes to reduce lead times while maintaining strict compliance with industry standards.
Case Study: Full Box Build Experience
Case Study: Full Box Build Experience
A global consumer electronics leader needed a fast and cost-effective route to market for a new consumer audio product. Traditional OEM models required managing multiple suppliers across the value chain, which created long lead times and added cost pressures.
FVG delivered a complete box build solution, consolidating electronics, acoustics, and finishing into a single integrated process. By front-loading Make/Buy decisions, running product and manufacturing ideation in parallel, and applying VAVE (Value Analysis / Value Engineering), FVG shortened lead times while maintaining quality and optimising cost.
Manufacturing Process:
Electronics Integration: Complete PCB assembly and integration within the product build.
Acoustic Engineering: Speaker drivers, enclosures, and sealing elements built for consistent sound performance.
Full Box Build: Precision-moulded parts, coatings, and labelling combined into a fully assembled, market-ready unit.
Outcome:
With vertical integration and a streamlined “Build to Order” approach, FVG delivered beta units within 6 months from tool-up. Manufacturing cost was held at 15% of RRP, half the typical OEM benchmark. Final production turnaround was reduced to only 4 weeks, demonstrating the strength of FVG’s full box build capability.