Box-Build, System Integration & Wire/Cable Harnessing

PCBA + harness + mechanical assembly for industrial, EV, and power electronics programs

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A finished electronic product is rarely a board on its own — it is a PCBA in a harness, in an enclosure, with mechanical fit, safety isolation, and end-product test. Indic's box-build practice integrates PCBAs, in-house cable and wire harnesses, mechanical assemblies, and EOL testing under one operating discipline —eliminating the hand-offs that fragment system-level quality.

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1. Custom Box-Build & System Integration

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For OEMs running build-to-order and configure-to-order programs where system-level integration discipline decides outcome.

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Build-to-Order & Configure-to-Order Box-Build

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Variant-aware kitting and routing  ·  MES-bound bills of process per configuration ·  First-article inspection per variant  ·  Configuration logic in SAP S/4HANA driving floor effectivity.

Builds: Box-Build    ·   Certifications: IPC-A-610 Class 2/3, ISO 9001

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Mechanical Assembly & Enclosure Integration

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Metal injection molding, plastic injection molding, sheet metal, extrusion,and die-casting via vetted Indian supplier network  ·  Enclosure fit, strain relief, and service-loop discipline  ·  Mechanical FAI per program.

Builds: Box-Build + Sub-Assembly   ·   Certifications: IPC-A-610

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System-Level Functional & EOL Test

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System-level FCT ·  EOL inspection  ·  Hi-pot per IEC 62368-1 where applicable  · Per-serial test records bound to MES.

Builds: Box-Build    ·    Certifications: IEC 62368-1, IPC-A-610

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IN PRACTICE

‍For a first-batch mass-production transfer to a new overseas lighting customer with no end-tester available,  Indic compensated with cross-functional ownership, layered process audits, and expanded first-article checks — zero rejections, 100%customer satisfaction, follow-on awards.

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2. Wire & Cable Harnessing

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For variant-heavy programs where harness reliability decides end-product yield and shipping defect rates.

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Multibranch Harnesses & Cable Assemblies

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Multibranch harnesses up to ~2,500 points  ·  Automotive-grade crimping with crimp-force monitoring  · 3D harness assemblies  ·  Today: built via vetted near-site supplier with full traceability and 100% electrical testing.

Builds: Harness    ·    Certifications: IPC/WHMA-A-620 Class 2 (Class 3for aerospace on request)

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Optical-Fiber & Hybrid Looms

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Optical-fiber harnesses  ·  Hybrid fiber + electrical looms  ·  100% continuity and hi-pot testing  ·  Bend-radius and strain-relief discipline.

Builds: Harness    ·    Certifications: IPC/WHMA-A-620 Class 2/3

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Process Quality Controls (Welding, Crimping, Potting)

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Ultrasonic welding  ·  Crimp-force monitoring per cycle  ·  Potting /over molding  ·  Low-pressure molding (LPM).

Builds: Harness + Sub-Assembly    ·   Certifications: IPC/WHMA-A-620

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IN PRACTICE

‍Indic's Phase II commitment brings harness manufacturing fully in-house — a ~1,500 sq ft dedicated cell inside the 80K+ sq ft expansion, eliminating outsource hand-offs and consolidating IPC/WHMA-A-620 Class 2 discipline (Class3 on request) under Indic's direct quality control.

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3. EV / Power Assembly Integration

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For EV powertrains, chargers, and power-electronics programs where PCBA+ harness + box-build must converge under hi-pot certification windows.

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High-Voltage Power Assemblies

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HV Battery Junction Box (BJB)  ·  Battery Disconnect Unit (BDU)  · Power Distribution Unit (PDU)  ·  HV AC and DC connectors integrated with harness sub-assemblies.

Builds: Box-Build + Harness    ·    Certifications: AEC-Q100/Q200, IATF16949

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Charger & Power-Electronics Integration

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On-Board Charger (OBC)  ·  3 kW 3-wheeler EV charger  ·  DC Fast Chargers  · EVSE charging infrastructure with parallelized PFC top/bottom SMT and concurrent box-build.

Builds: PCBA + Box-Build    ·    Certifications: AEC-Q, ARAI certified (3kW), IEC 61851

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Hi-Pot Test per IEC 62368-1

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Safety isolation verification across power-electronics box-builds  · Audit-ready hi-pot records bound to serial  ·  Workmanship per IPC-A-610 Class 2 or Class 3 depending on field-reliability requirements.

Builds: Box-Build    ·    Certifications: IEC 62368-1, IPC-A-610 Class 3 where applicable

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IN PRACTICE

‍On a 3 kW 3-wheeler EV charger program facing an ARAI certification window, Indic parallelized PFC top/bottom SMT and started box-build before all boards were complete — delivering a 4-day assembly cycle (vs. a legacy ~2-week cycle)and removing import dependency through localized component sourcing.

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4. Certifications & Standards Supporting Box-Build & Harnessing

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5. Supplier Ecosystem & Supporting Capabilities

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Schedule a discovery call at indicelectronics.com ·  or email info@indicelectronics.com to discuss your box-build or system-integration program.

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