Box Builds & Enclosures
- Avionics LRUs
- ATR enclosure assemblies
- Rack-mount systems
- Field-deployable units
- Test equipment enclosures
Displays, PCBAs, harnesses, power, I/O, and mechanical hardware integrated into tested, installation-ready units.
Polytronix makes complete box builds and enclosure assemblies - avionics LRUs, ATR enclosures, and rack-mount systems - integrating displays, PCBAs, power, harnesses, I/O, and mechanical hardware into tested, qualified units ready for installation for aerospace and defense programs.
Overview
Polytronix provides complete box build and enclosure assembly services for aerospace and defense programs. We integrate displays, PCBAs, power systems, harnesses, I/O hardware, and mechanical components into tested, qualified units ready for installation. Deliverables include complete enclosure assemblies, line-replaceable units (LRUs), and system housings across ATR, rack-mount, portable, and custom form factors.
Ruggedization is engineered into the build rather than added afterward: EMI shielding, thermal management, and shock and vibration isolation are integrated at the assembly level, with environmental qualification supporting QPL-7788, MIL-DTL-7788, MIL-STD-810, and customer-defined environmental requirements: including temperature, humidity, altitude, shock, vibration, and salt-fog exposure. Internal wiring is routed and terminated by our in-house cable and harness shop in compliance with IPC/WHMA-A-620 Class 2/3.
We support consignment and full-turnkey programs across prototypes, low minimum order quantities, high-mix work, and large production runs, with traceable workflows, ESD-controlled environments, in-house testing infrastructure, and serialized configuration control. Workmanship is performed and certified to IPC-A-610 and IPC J-STD-001 at Class 2 and Class 3, with ITAR-controlled production available for U.S. defense customers.
At a Glance
| Certifications | AS9100D, ISO 9001, ISO 13485, ISO 14001, IATF 16949, ITAR |
|---|---|
| Program Fit | Aerospace, Defense, Industrial, Test Equipment |
| Core Strengths | LRUs, Enclosures, Harness Integration, Test |
| Typical Deliverables | Box Builds, LRUs, Enclosure Assemblies |
| Order Quantities | Prototypes to Production Runs |
Box Build Scope
Enclosures & Form Factors
- ATR enclosures and avionics LRUs
- Rack-mount and cabinet-level systems
- Portable and field-deployable units
- Custom enclosures (plastic, metal, and customer-supplied)
- Build-to-print custom systems
Panels & Power Systems
- Display and instrument-panel enclosures
- Power supply and power-distribution boxes
- Control panels and HMI assemblies
Electro-Mechanical Integration
- Electro-mechanical assemblies
- Electro-pneumatic assemblies
Test & Support Equipment
- Test equipment enclosures and ATE racks
- Ground-support equipment boxes
Relevant Applications
Aerospace
ATR LRUs, instrument-bay enclosures, mission-system housings, and avionics units for fixed-wing, rotary-wing, and unmanned platforms, built under AS9100D and to MIL-DTL-7788 and MIL-STD-810 environmental requirements.
Explore Aerospace & DefenseDefense
Ground-support equipment, mission-system enclosures, and ruggedized control boxes for ITAR-controlled defense programs, with EMI shielding and shock/vibe isolation engineered to MIL-spec requirements.
Explore Military ProgramsIndustrial
Control cabinets, HMIs, drive enclosures, and instrumentation boxes for manufacturing, energy, and utility customers, qualified under IATF 16949 and ISO 9001 quality systems.
Explore Industrial EquipmentTest Equipment
Automated test equipment racks, environmental test fixtures, calibration stations, and flight-line test sets requiring rugged, high-cycle interconnects and serviceable mechanical integration.
Explore Simulation & TrainingRelevant Capabilities
Custom box build design and engineering
DFM/DFT engineering supports early concept through production handoff. Engineering reviews cover mechanical fit, thermal load, EMI containment, cable routing, serviceability, and yield risk before first article, reducing program risk and accelerating time-to-market.
Explore EngineeringEnclosure fabrication and integration
Assembly of plastic, metal, and customer-supplied enclosures in ATR, rack-mount, portable, and custom form factors. Includes fasteners, gaskets, ventilation, mounting hardware, and labeling, with in-house machine-shop support for housings, bracketry, and mechanical modifications.
Explore MachiningDisplay, PCBA, and sub-assembly integration
Installation of displays, PCBAs, power supplies, fans, switches, relays, and electromechanical sub-assemblies into final enclosures. Includes verification of mechanical fit, mating connections, and grounding and bonding before final closure.
Explore DisplaysPower and I/O integration
Integration of internal power systems, power-distribution wiring, and front- and rear-panel I/O connectors. Includes verification of voltage rails, isolation, and connector pinout against customer specification.
Explore Electro-MechanicalCable and harness routing
Internal harness installation and routing by our in-house cable, wire, and harness shop. Tie-downs, P-clamps, lacing, strain relief, service loops, and shield-bonding are performed per IPC/WHMA-A-620 Class 2/3.
Explore HarnessesEMI shielding
Installation of EMI gaskets, conductive seals, board-level shielding cans, and shielded backshells to contain emissions and protect against susceptibility per applicable MIL-STD-461 and customer EMC profiles.
Explore RuggedizationThermal management
Integration of heat sinks, thermal interface materials, conduction-cooled card frames, fans, and air- or cold-plate cooling solutions to maintain component junction temperatures within specification across the operating envelope.
Explore RuggedizationShock and vibration isolation
Installation of wire-rope, elastomeric, and viscoelastic isolators, captive hardware, and shock-rated mounting to protect internal electronics and displays in airborne, vehicular, and ground-support environments.
Explore RuggedizationEnvironmental qualification support
Build configuration tailored to MIL-DTL-7788 and MIL-STD-810 environmental requirements including temperature, humidity, altitude, shock, vibration, and salt-fog plus support for customer-specific environmental qualification. Coordination with qualification labs for first-article and lot-acceptance testing.
Explore RuggedizationStandards and Compliance
IPC workmanship standards
- IPC-A-610 - Acceptability of Electronic Assemblies, Class 2/3Conformance
- IPC J-STD-001 - Soldered Electrical and Electronic AssembliesConformance
- IPC/WHMA-A-620 - Acceptability of Cable, Wire, and Harness AssembliesConformance
Environmental and EMC standards
- MIL-DTL-7788 - Backlit panel and lighting environmental requirementsRegistered
- MIL-STD-810 - Environmental engineering considerations and laboratory testsConformance
- MIL-STD-461 - Electromagnetic interference (EMI/EMC) requirementsConformance
Additional compliance
- ANSI/ESD S20.20 - ESD-controlled production environmentsReferenced
- RoHS / Lead-Free - environmental compliance optionsConformance
Third-party recordConformance claimedReferenced
MIL-DTL-7788 — U.S. Defense Logistics Agency (qualifying activity for the QPL-7788 listing). Certificates of record →
Frequently Asked Questions
- Who makes box builds and enclosure assemblies for avionics LRUs?
- Polytronix makes complete box builds and enclosure assemblies for aerospace and defense programs, integrating displays, PCBAs, power systems, harnesses, I/O hardware, and mechanical components into tested, qualified units ready for installation. Deliverables include complete enclosure assemblies, line-replaceable units (LRUs), and system housings across ATR, rack-mount, portable, and custom form factors.
- How does Polytronix ruggedize box builds?
- At Polytronix, ruggedization is engineered into the build rather than added afterward: EMI shielding, thermal management, and shock and vibration isolation are integrated at the assembly level. Environmental qualification supports QPL-7788, MIL-DTL-7788, MIL-STD-810, and customer-defined requirements including temperature, humidity, altitude, shock, vibration, and salt-fog exposure.
- Does Polytronix route internal wiring and offer turnkey box build programs?
- Polytronix routes and terminates internal wiring through its in-house cable and harness shop in compliance with IPC/WHMA-A-620 Class 2/3. We support consignment and full-turnkey programs across prototypes, low minimum order quantities, high-mix work, and large production runs, with traceable workflows, ESD-controlled environments, in-house testing, and serialized configuration control.
- What workmanship standards apply to Polytronix box builds?
- Polytronix box build workmanship is performed and certified to IPC-A-610 and IPC J-STD-001 at Class 2 and Class 3, with ITAR-controlled production available for U.S. defense customers. EMI containment is built to applicable MIL-STD-461 and customer EMC profiles, with environmental qualification to MIL-DTL-7788 and MIL-STD-810.
Discuss Your Box Build Requirements
Send your enclosure drawing and BOM. We confirm mechanical fit, thermal load, and EMI containment before first article.
Quality & Compliance
Polytronix maintains active third-party registrations spanning aerospace, medical, automotive, and environmental quality systems, verified by accredited registrars.
View Certifications- Registered: AS9100DAerospace QMS
- Registered: ISO 9001:2015Richardson, TX
- Registered: ISO 13485:2016Medical devices
- Registered: ISO 14001:2015Environmental
- Registered: IATF 16949:2016Automotive
- Registered: FAA Part 145Repair Station 8PTR524C
- Compliant: EASA Part 145US–EU bilateral recognition
- Registered: ITARDDTC registration