Systems Integration
We ship a finished product, not a pile of parts.
PPSI takes the boards, harnesses, and hardware that make up your product and integrates them into a complete, tested unit. Box build, electromechanical assembly, conformal coating, firmware loading, and final pack-out all happen on one floor, so the same AS9100D quality system that governs the bare board follows the product all the way to the shipping carton.
How a build comes together
A box build is where subassemblies become a product. We run integration as a controlled sequence so the unit that ships is the unit your drawing describes.
Kitting and staging
Boards, harnesses, enclosures, and hardware are verified against the bill of materials and kitted per unit, so every build starts complete and traceable.
Mechanical and enclosure assembly
Chassis and enclosures are built up with fasteners, standoffs, thermal interfaces, and mounting hardware torqued and recorded to the assembly drawing.
PCBA and harness integration
Circuit board assemblies are installed, harnesses are routed and dressed, and connectors are mated and verified against the pinout. Cable and harness work is built in-house to IPC/WHMA-A-620.
Environmental protection
Conformal coating (acrylic, urethane, or silicone) and potting or encapsulation are applied in-house, with 3D-printed masking and fixtures for fast turnaround on custom geometry.
Firmware load and functional test
Customer-supplied firmware is loaded and the unit is run through your functional test procedure to confirm the whole system operates, not just the individual boards.
Serialization and pack-out
Labels, serialization, and a final cosmetic inspection complete the build before it is packaged to your spec or in standard ESD-safe packaging for shipment.
What we integrate
Mechanical, electrical, and environmental work that turns a set of subassemblies into a deliverable unit.
Mechanical integration
- Enclosure and chassis assembly
- Hardware, fasteners, and standoffs
- Thermal management and interfaces
- Labels, placards, and markings
Electrical integration
- PCBA installation and mounting
- Cable routing, dress, and tie-down
- Connector mating and pinout checks
- Power supply and display integration
Finishing and delivery
- Conformal coat and potting in-house
- Firmware loading and configuration
- Serialization and unit-level records
- Custom or ESD-safe packaging
Verified at the system level before pack-out
Boards are inspected on the line, but a finished unit has to be checked as a whole. Every integrated system passes through a documented verification sequence before it is packaged.
Mechanical inspection
Hardware torque verification, fit checks, and visual inspection to the assembly drawing and workmanship standards.
Electrical verification
Continuity, connector pinout, and power-on checks confirm the unit is wired and powered correctly.
Functional test
Your test procedure is run against the assembled unit to verify full system operation, not just board-level function.
Cosmetic inspection
Enclosure finish, label placement, and overall appearance checked against acceptance criteria.
Packaging verification
Correct packaging materials, ESD protection, and the right documentation included with every shipment.
Traceable records
Serialization and AS9100D records tie each unit back to its components, processes, and test results.
One supplier, from bare board to boxed product
Most integrators receive boards and harnesses from somewhere else, which means every defect turns into a finger-pointing exercise between vendors. At PPSI the boards, the harnesses, and the integration come from the same floor, so accountability never leaves the building.
That single-source model means fewer handoffs, one quality system end to end, and one team to call when a build needs a change. Conformal coating and potting are done in-house with 3D-printed tooling, so environmental protection does not add an outsourcing delay.
Where our systems ship
We deliver finished, tested units for programs where a working product matters more than a bag of subassemblies.
Explore Our Other Capabilities
PPSI offers a full suite of manufacturing services to support your entire product lifecycle.
PCB Assembly
Surface Mount, Through-hole, and Quick Turn capabilities with placement down to 01005.
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Cable & Harness
Custom cable assemblies and wire harnesses built to IPC/WHMA-A-620 standards.
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