Production Process in Poland
100% Polish Production – From Design to Shipping
When you say "Made in Poland," with PowerBox, it's not just a sticker. It's a reality at every stage of production – from the first design sketch, through electronics assembly, to final testing and packaging.
In this article, we will take you behind the scenes of the production of PowerBox charging stations and show you how Polish technology for electromobility is created .
Stage 1: Design and Recipe – Polish Engineering
It all starts in a Polish design office , where a team of electronics engineers and electromobility specialists create:
✅ Electrical diagram – power supply, security, communication system
✅ PCB design – component layout, conductive paths
✅ Production recipe – list of all components (BOM - Bill of Materials)
✅ Control software – firmware for the microcontroller
Why is this important?
Polish design means complete control over quality and safety . Each element is designed with the Polish climate, European standards, and the needs of EV users in mind.
Stage 2: Component Completion – Highest Quality
Once the design is approved , all components are assembled :
🔌 Electronic components:
- Microcontrollers (the brain of the station)
- Power relays (charge control)
- Resistors, capacitors, diodes (RLC elements)
- Current and voltage sensors
- Communication modules (RFiD, Wi-Fi)
🏭 PCB production:
- Printed circuit boards (PCB) manufactured according to Polish design
- Multilayer PCBs with precise traces
- Quality control of each panel before assembly
All components come from reliable suppliers who meet ISO quality standards and safety certificates.
Stage 3: Pick&Place Assembly – Robot Precision
This is where the magic of automation happens ! 🤖
The Pick&Place machine is an advanced robot that:
⚙️ Extracts microscopic components from power ribbons
🎯 Places them with a precision of 0.01 mm on the PCB
⚡ Assembles hundreds of components in a minute – resistors, capacitors, integrated circuits
🔬 Controls the position of each element using vision cameras
SMD (Surface Mount Device) assembly process:
- Applying solder paste – precise dosing onto PCB pads
- Pick&Place – the robot places RLC components and integrated circuits
- Reflow oven – the board passes through the oven, the paste melts and solders the components
- Cooling – the plate cools down in controlled conditions
Why Pick&Place?
Manually assembling hundreds of microscopic components would be impossible. The Pick & Place machine provides:
✅ Precision – every element exactly where it should be
✅ Repeatability – each plate is identical
✅ Speed – production of hundreds of boards per day
✅ Quality – minimizing human errors
Stage 4: PCB Quality Control – Zero Compromise
After assembly, each PCB undergoes rigorous quality control :
🔍 AOI (Automated Optical Inspection):
- The camera scans the entire disc in high resolution
- Detects missing components, misalignments, and soldering errors
- Compares with a reference standard
🔬 X-ray inspection (for critical components):
- Checks the quality of soldering under BGA components
- Detects cracks, voids, and short circuits
⚡ ICT Electrical Tests (In-Circuit Test):
- Checks the conductivity of the paths
- Tests resistor and capacitor values
- Detects short circuits and open circuits
Only boards that pass all tests move on to the next stage!
Stage 5: Programming and Serial Numbers – Individual Identity
Each PCB goes to the programming department , where:
💾 Firmware Injection:
- Control software loaded into the microcontroller
- Calibration of current and voltage sensors
- Configuring security parameters
🔢 Serial Number Assignment:
- Each PowerBox station receives a unique serial number
- The number is stored in non-volatile memory
- Enables identification, warranty and service
📊 Functional board tests:
- Vehicle charging simulation
- RFiD communication test
- Checking all security features
Why is this important?
The serial number is the passport of each station – it allows you to track production history, software updates and possible warranty repairs.
Step 6: Mounting to the Housing – Putting the Whole Together
The tested PCB goes to the final assembly department :
🔧 Mechanical assembly:
- Installing the board in an IP54 enclosure
- LED display installation
- Installing the RFiD reader
- Installing a Type 2 connector with a 5m cable
- Installing the power socket
🔌 Wiring:
- Connecting the power cables
- Connection of sensors and communication modules
- Securing connections with heat-shrinkable covers
🛡️ Sealing:
- Installation of IP54 seals
- Protection against moisture and dust
- Housing tightness check
Stage 7: Final Testing – Every Station Must Be Functional!
This is the most important stage of production ! ⚡
Each PowerBox station undergoes comprehensive functional tests that simulate real-world conditions of use:
Test 1: Power and Security
✅ Checking the 400V three-phase power supply
✅ Residual Current Device (RCD) Test
✅ Overvoltage protection test
✅ Short circuit protection test
Test 2: Vehicle Charging (Simulation)
✅ Connecting an EV vehicle simulation tester
✅ Control Pilot (CP) communication test
✅ Power regulation test (1.4 kW - 11/22 kW)
✅ Emergency Stop Test
Test 3: RFiD Authorization
✅ NFC card reader test
✅ Adding and removing user cards
✅ Unauthorized Access Blocking Test
Test 4: Display and Communication
✅ LED test (blue, yellow, green, red)
✅ Error Message Test
✅ Communication module test (if equipped)
Test 5: Resistance to External Conditions
✅ IP54 tightness test (rain simulation)
✅ Extreme temperature test (-45°C / +55°C)
✅ IK6 mechanical resistance test
Why is this so important?
Each PowerBox station that is delivered to the customer must be 100% functional and tested.
We do not send products "on trial" - we send ready-made, proven solutions that will work for years without problems.
This is our guarantee of quality and responsibility for user safety.
Step 8: Packaging and Shipping – Safe Delivery
After passing all tests, the PowerBox station is:
📦 Packaged:
- Protective cardboard packaging
- Foam filling for shock protection
- Assembly instructions and warranty cards
- RFiD cards included
📋 Documented:
- Quality certificate
- Warranty card with serial number
- Installation and use instructions
🚚 Sent to customer:
- Safe courier transport
- Tracking number
- Transport insurance
Why Does Polish Production Matter?
1. Quality Control at Every Stage
Manufacturing in Poland means complete control over every stage—from design to shipping. We don't outsource production to countries with lower standards.
2. Fast Service and Support
Problems? Questions? Service in Poland means quick response, immediately available spare parts, and support in Polish.
3. You support the Polish economy
By purchasing PowerBox, you support:
- Polish jobs
- Polish engineers and technicians
- Polish innovation in electromobility
4. European Standards and Certificates
Polish production = European quality standards :
- CE standards
- Safety certificates
- Compliance with EU directives
Summary – From Design to Your Home
PowerBox production process in Poland:
- ✅ Design and recipe – Polish engineers
- ✅ Component assembly – highest quality
- ✅ Pick&Place assembly – robot precision
- ✅ PCB quality control – zero compromises
- ✅ Programming and serial numbers – individual identity
- ✅ Mounting to the housing – assembling the whole thing
- ✅ Final tests – every station checked!
- ✅ Packaging and shipping – safe delivery
Each PowerBox station is the result of the work of Polish specialists, modern technologies and rigorous testing.
This isn't just a charger – it's Polish technology you can count on for years to come! 🇵🇱⚡
📧 Do you have questions about PowerBox production?
Email: info@everev.pl
Phone: +48 71 889 01 30
Website: www.everev.pl
Ever EV – Your energy. Our technology. Polish quality.