Antenna placement decides RF performance
For a connected device, antenna placement inside the housing decides RF performance more than which radio chip is used. Metal nearby detunes the antenna. Plastic with conductive paint detunes the antenna. Cables routed across the antenna detune the antenna.
Box-build assembly that maintains antenna clearance to spec, in the same orientation across every unit, gives consistent RF performance batch to batch. Box-build that varies antenna orientation gives inconsistent field reports.
The fix is in the assembly drawing: antenna position, orientation, clearance distance, and prohibited materials within the clearance zone. Production then enforces it.
Gasketing for IP rating
Devices rated IP54, IP65, or IP67 depend on gasket compression. Gasket compression depends on assembly torque on the housing fasteners. Inconsistent torque means inconsistent IP rating.
Box-build assembly with controlled torque (calibrated drivers, documented torque values) produces consistent IP performance. Sample IP testing per batch catches the cases where the torque was right but the gasket was damaged.
Labels go on after final test
A unit labeled before final test that fails the test is wasted label cost (small) and wasted operator time (larger) and risk of mislabeled units shipping (very large).
The discipline: final functional test gate, then label, then pack. Always in that order.
Packaging spec
Packaging is part of box-build, not an afterthought. The packaging spec includes:
- Inner and outer carton dimensions
- Foam, blister, or molded pulp insert design
- Desiccant if needed
- Documentation included (quick start, certifications, accessory list)
- Carton label (master carton serial range, count, weight)
- Pallet pattern if applicable
A connected device packed inconsistently survives shipping inconsistently. Damage rates climb.
What good box-build looks like
- Assembly drawing with antenna placement, gasket spec, torque values
- Test gate before labeling
- Per-unit traceability log including operator and station
- Sample IP testing per batch
- Packaging spec attached to the project, not improvised
Sources
- IPC, "Conformal Coating and Encapsulation"
- Antenna manufacturer reference designs (Taoglas, Pulse, etc.)
- IEC 60529 (IP rating test method)
- GS1 packaging and labeling guidelines