DITAIHVAC control
box assembly.
An HVAC control box brought together more than 40 components, including plastic housings, metal parts, circuit boards, antennas and a condensate pump. DITAI worked through prototype assembly, production preparation and functional testing with the customer, paying attention to how the complete unit came together.
Batch assembly photographed during the project.
The assembly scope needed a shared understanding
The project combined plastic part assembly with electronics and a condensate-handling system. Before committing, we discussed the technical support and component-supplier coordination the work would require. We raised the areas outside our established experience directly with the customer.
The customer explained the assembly further and offered hands-on support. Following those discussions, we agreed to proceed. Our work covered prototype assembly, tooling and material preparation, batch assembly and packaging. The process used the customer’s system for PCB programming and customer-supplied equipment for functional testing.
Those interfaces mattered to the project: the mechanical build had to accommodate electronic components, and the completed unit had to enter the customer’s test process. Discussing the support needed before assembly gave both teams a concrete basis for cooperation.
Customer identity and identifying project details are withheld.
Working through the condensate-module assembly with 3D-printed plastic parts.
A complete prototype assembly before production tooling
We first used 3D-printed versions of the plastic parts to check the fit of the complete assembly. The prototype work brought the actual components together inside their intended housings.
The condensate module combined a water pump and sensors with its plastic parts. The power module brought the power board into its enclosure. The logic module involved programming the PCB through the customer’s system, connecting the antenna and fitting the board into its housing.
The engineering value of this trial build was the opportunity to examine the interfaces together. The pump and sensors occupied the condensate housing. The circuit boards had to fit their enclosures, with their connectors available for the next assembly step. Each completed module then had to fit within the main housing. Looking at the actual assembly made these relationships easier to discuss than reviewing the plastic parts separately.
For an assembly of this type, useful review questions include whether a connector can be reached with the module in position, whether a lead or tube crosses a closing surface, and whether a fixing can be installed without forcing the surrounding parts. These are engineering review considerations, rather than defects reported in this project.
The 3D-printed parts supported this fit review before production tooling. Production material performance and long-term reliability require their own evidence; a successful prototype assembly does not establish either.
Four modules gave the assembly a clear sequence
The project divided the work into a condensate module, a power supply module, a logic module and the main housing assembly.
Our team assembled the housing from its constituent parts, including the sheet metal and extruded sections. The three internal modules then entered the housing in sequence and were secured with screws.
The three internal prototype modules before integration into the main housing.
The sequence distinguishes two assembly questions: whether the components fit within each module, and whether those modules fit and connect within the main enclosure. A completed module is an intermediate build stage. The final integration and functional test still have work to do.
The project photographs record component preparation, assembly work and completed modules. For a customer reviewing the build remotely, these views provide reference points for discussing a connection or installation step. They show the work inside the enclosure before the final exterior conceals it.
Functional testing followed final assembly
The customer supplied equipment for testing the assembled units. The prototype-stage record shows the test setup, and the production process requires each completed E-box to be tested. The stated checks cover the pump, water flow and sensors.
These checks address different aspects of the assembled system. A pump that runs does not, on its own, demonstrate that water moves through the intended path. Observing flow and checking sensor responses adds information that a visual inspection of the closed enclosure cannot provide. This is why the functional check is a significant part of the assembly story.
The process puts the label after the test result. When a unit passes the specified test, the system generates a QR code for printing and attachment to the underside of the box. That order gives the operation a defined completion step: assemble the unit, run the specified checks, then apply the label following a passing result.
- 01
Assembled unit
Each completed E-box enters the specified test process.
- 02
Functional checks
Water flow, sensors and pump checks using customer-supplied equipment.
- 03
Pass label
After a passing result, print and attach the generated QR-code label.
The checks described here are the documented project functions. Test limits and wider product qualification remain separate matters. This case does not claim electrical safety certification or validation of every operating condition.
Batch assembly and packaging remained part of the job
The project progressed into tooling and material preparation, followed by batch assembly. The photographs show the transition from white prototype plastic parts to production components, with groups of modules and main housings at different stages of integration. This documents progression into a production build, rather than stopping at a demonstration sample.
Packaging received its own attention. We developed a dedicated tear-open carton with separate compartments for the assembled units. The project photograph shows each unit occupying its own section, with cardboard partitions between adjacent products.
The partitions provide physical separation between products sharing the carton. For the customer, the assembly work therefore extends into how the units are arranged and handled for delivery. The packing arrangement is documented here; transport-test performance is outside the scope of this case.
Power modules prepared during the batch-assembly stage.
Dedicated carton with separate compartments for the assembled units.
What this project demonstrates
The documented result is a project carried through complete prototype assembly into batch production, with functional checks specified for each finished unit and packaging developed for the assemblies.
The work connected several responsibilities that the customer needed addressed together. Prototype assembly brought the components into their intended spaces. Modular construction provided a defined build sequence. Customer-supplied testing checked stated functions after integration, and the carton gave the finished assemblies a dedicated packing arrangement.
Our contribution was the work between the individual parts and the completed assembly, carried out in cooperation with the customer. That is the approach we bring to projects with unfamiliar details: raise the technical questions early, work through the physical build and keep attention on the checks needed at completion.
Discuss your
enclosure assembly.
Share the enclosure drawing or assembly overview, the components involved and the functions the finished unit must demonstrate. We can review the assembly scope with you and identify where customer-supplied equipment or specialist support will be needed.
For a new assembly project, the review should also establish the drawing and component revisions, firmware and test-program ownership, sample acceptance criteria and the handling of a failed test.
If the project is confidential, arrange an NDA with us before sending sensitive files.
Have a Thermoforming Project?
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