Box Build: Precision, Quality Inspection, and Engineering Excellence

At STS Defence, our reputation for delivering reliable, high-performance box build assemblies is built on one core principle: uncompromising quality. Serving the aerospace and defence sectors, we provide mission-critical solutions that combine precision engineering, robust manufacturing, and meticulous quality inspection throughout every phase of the box build process.

A Culture of Quality from Design to Delivery
Box build is not just assembly, it’s a tightly controlled, quality-driven process where every detail matters. Our products are engineered for the most demanding environments, and every step is governed by rigorous inspection protocols to ensure compliance with the highest standards of defence regulation.

Design and Engineering: Built for Inspection
The process begins with a highly collaborative design phase. Our experienced engineering teams work closely with customers to develop solutions that meet strict operational, environmental, and regulatory requirements. Designs are validated through simulations and subject to design for inspection (DFI) principles, ensuring quality is embedded and verifiable from the outset.

Using advanced CAD and modelling tools, we map out assemblies with inspection accessibility in mind, enabling efficient verification at every critical stage.

Procurement and Traceability of Components
We source only from trusted, pre-approved suppliers. Each component undergoes incoming quality inspection (IQI), where we check for:

• Defence-grade specification compliance
• Certification and full traceability
• Visual and dimensional accuracy
• Tolerance-based performance testing

This ensures every part meets our quality expectations of building a reliable foundation for system integration.

Assembly and In-Process Quality Control
Our skilled assembly teams follow standardised work instructions, supported by in-process quality control (IPQC) at key intervals. Inspections during assembly include:

• Visual checks for component alignment and soldering integrity
• Work complexity
• Torque/tension validation on fasteners and connectors
• Wiring continuity and resistance testing
• Real-time quality logging for traceability

Embedded quality inspectors identify deviations early, supporting our right-first-time approach to minimise errors.

Rigorous Testing and Quality Assurance
After assembly, each unit enters a multi-tiered quality assurance and testing phase. Using calibrated tools and documented protocols, our QA teams validate system integrity through:

• Electrical Testing: Circuit verification and signal integrity
• Functional Testing: Simulated operational performance
• Endurance Testing
• Environmental Stress Screening (ESS): Thermal cycling, vibration, humidity
• Software/Firmware Validation: Performance, fail-safes, compatibility
• Final Inspection: Visual and dimensional conformance

Each inspection step is recorded, ensuring full traceability and compliance.

Final Assembly, Inspection, and Delivery Assurance
Final integration includes thermal solutions, protective enclosures, and client-specified interfaces. A final quality inspection ensures:

• Assembly completeness via structured checklists
• Client-specific requirements are met
• Secure, compliant packaging for safe transit

All units undergo and must pass rigorous quality gates to ensure operational readiness.

Post-Delivery Quality Support
Our commitment doesn’t end with delivery. We offer:

• Maintenance and repair under strict QA protocols
• In-service inspection support
• Root Cause and Corrective Action (RCCA) analysis
• Reliability tracking for continuous improvement

Quality You Can Depend On
At STS Defence, our box build capability is not just a manufacturing service, it’s also a strategic partnership rooted in quality, precision, and performance. From initial design to post-delivery support, every process is engineered for mission-critical reliability. With our deep expertise, rigorous inspection regime, and unwavering standards, customers can trust that what we deliver is built to perform.