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Build to Print. Build to Last.

Your Partner For All Your Build-To-Print Needs

What is Build-to-Print?

Build-to-print services provide full turnkey assembly of your equipment replication project including all purchasing, documentation management, assembly labor, inspection, testing, and worldwide shipping. Ball Systems can also support finalizing your design or updating older equipment to modern components.

We have an integrated team of experts for our build-to-print customers:

  • Project managers with engineering backgrounds
  • Procurement team to help with obsolete or hard to find material
  • Production technicians with diverse skillsets
  • Design engineers (Software, Electrical, Mechanical, Controls)

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Build-to-print assembly and low to mid-volume production.

Ball Systems develops build-to-print systems through robust processes and experts working to extend your own team in a way that flexibly meets your needs. Each step of our process follows rigorous controls to ensure your system is built to meet your needs. Our teams resolve obsolescence and design challenges along the way through our extensive network of specialized suppliers and internal design engineering team. Our build-to-print system deliveries range from single systems to orders of up to 1,500 systems/year.

Build-to-Print Capabilities

  • Build-to-print manufacturing
  • Low and medium volume production
  • Rework, remanufacture and repair
  • Testing, validation and verification services
  • Custom and COTS test equipment/cabinet assembly
  • Printed circuit board (PCB, PCA, and CCA) design and assembly
  • Final product and subassembly manufacturing
  • Panel wiring and electrical enclosure fabrication & assembly
  • Custom mechanical manufacturing & assembly
  • Custom and production cable assembly
  • Design for manufacturing (DFM) and design for test (DFT)
  • Power distribution equipment assembly
  • Component sourcing
  • Traceability
  • Metal fabrication and mechanical assembly

 

Manufacturing and Assembly Services

Design and Build or Build-to-Print

Ball Systems can design your product if required, then seamlessly fulfill orders, and ship direct to your factory, distribution center, or to your customers. Your product will be built with refined processes by tenured technicians who are skilled at ensuring consistency while also flexibly managing customer changes.

Concurrent Engineering

Our team excels at updating and optimizing designs for next-generation products while also building to meet current demand. Ball Systems’ designs reduce manufacturing and tooling costs and ease the transition to contract manufacturing.

Rework and Remanufacturing

Our staff has been trained and our processes manufacturing systems have been designed to address the oftentimes fast-moving and uncertain realities of rework situations. Our team of project managers are skilled at reviewing your requirements and identifying optimal implementation and manufacturing processes to accomplish your needs.

Sourcing and Transition to High-Volume Manufacturing

Not only do we produce documentation necessary for the transition to high-volume manufacturing, but we also help you identify the right manufacturing partner. We have contacts with many domestic and international firms to help get you started.

Partner with Ball Systems for:

  • Build-to-print and build-to-spec
  • Prototypes
  • Design for manufacture (DFM) & Design for test (DFT)
  • Manufacturing planning and program management
  • Process and assembly instructions
  • Purchased part specification and sourcing
  • Packaging design
  • Detailed bill of materials (BOM)
  • Vendor management
  • Manufacturing bid packages
  • Testing and quality assurance
  • Engineering services
  • Manufacturing services
  • Product development expertise

 

Contact us today to let us help you with your build-to-print needs.

From the Blog

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Project Gallery

Custom designed test circuitry and low-volume production of test cards.

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Rack of LBX Load Boards

Test control boxes for major computer OEM server test environment with custom board design and production.

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MRBS Power Cycling Boxes

Design and production of high-volume PCAs used in server test environment.

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RBS Power Cycle Control Boards

Custom wired and designed Virginia Panel (VPC) Interchangable Test Adapter to provide test interconnect.

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 Interchangeable Test Adapter (ITA)

High density custom backplane design and fabrication.

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Custom Connector Backplane

Custom cable harness design and build.

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Custom Automotive Cable Harness

Custom modular designed signal routing and management box for NI PXI aerospace test system.

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Custom modular designed signal routing and management box for NI PXI aerospace test system.

Custom probe blocks and interface circuitry for burn-in cart fixtures.

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Burn-in Cart Fixture

256-pin custom test cable harness

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256-pin Custom Test Cable Harness

1U 19-inch power cycling box

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1U 19-inch Power Cycling Box

Custom designed control box for a medical research lab device with precision motion control and vision integration.

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Prosolia Control Box

Turnkey contract manufacturing for major railyard and locomotive engineering company.

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Wireless Rail Yard Track Switching Control Box

Custom designed communication board and molded housing that incorporates custom firmware design.

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Hydra Comm Boards

Toroidal inductors designed to application, and manufactured in-house.

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KPA900 Programmer Software

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KPA900 Programmer Software

Custom designed portable test box to emulate factory test in self-contained platform that includes custom firmware, FPGA, etc.

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Custom designed NI PXI test console, including custom backplane, card cage, and custom test cards.

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Custom designed NI PXI test console, including custom backplane, card cage, and custom test cards.

Custom wired Virginia Panel (VPC) Interchangable Test Adapter (ITA), this project is custom-designed and wired to provide test interconnect.

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Custom wired Virginia Panel (VPC) Interchangable Test Adapter (ITA), this project is custom-designed and wired to provide test interconnect.

Custom designed programming station to provide simultaneous EEPROM in-line programming in high-speed line.

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Custom designed programming station to provide simultaneous EEPROM in-line programming in high-speed line.

Custom designed, low profile NI PXI test console, including custom backplane, card cage, and custom test cards.

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Custom designed, low profile NI PXI test console, including custom backplane, card cage, and custom test cards.

Custom designed PXI Test Console, including NI Chassis and VPC Interconnect.

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Custom designed PXI Test Console, including NI Chassis and VPC Interconnect. 

EEPROM verification fixture, including custom mechanical and electrical design and automation.

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EEPROM verification fixture, including custom mechanical and electrical design and automation.

Custom designed test equipment cable harness, including VPC iCon series quick disconnect and product connectors.

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Custom designed test equipment cable harness, including VPC iCon series quick disconnect and product connectors.

Automation system control panel and enclosure.

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Automation system control panel and enclosure.

Custom test cable harness for portable automotive audio system tester.

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Custom test cable harness for portable automotive audio system tester.

Portable suitcase tester for automotive audio systems that is designed to emulate production functional test environment.

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Portable suitcase tester for automotive audio systems that is designed to emulate production functional test environment.

8-bay universal programming platform for EEPROM programming and verification with custom PCAs and integrated custom software.

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8-bay universal programming platform for EEPROM programming and verification with custom PCAs and integrated custom software.

Custom test station for hybrid technology engine control modules that meets high voltage, high power, and automation requirements.

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Custom test station for hybrid technology engine control modules that meets high voltage, high power, and automation requirements.

Pneumatically controlled conditioning nest for engine control module that is custom mechanical, electrical, and firmware design.

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Pneumatically controlled conditioning nest for engine control module that is custom mechanical, electrical, and firmware design.

Custom designed engine module tester interface, including custom probe interface, and ergonomic mechanical actuation.

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Custom designed engine module tester interface, including custom probe interface, and ergonomic mechanical actuation.

Custom designed test equipment cable harness, including VPC iCon series quick disconnect and product connectors.

Read More.

Custom designed test equipment cable harness
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Partners We Work With

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