Custom Enclosure

  • An enclosure is required to shield electric or electronic equipment against electric shock, and protection against hazardous, non-hazardous, and other specified environmental conditions designated by the enclosure’s ingress protection (IP) rating.
  • Enclosures protect printed circuit boards and other electrical equipment in diverse environments, such as everyday consumer use, industrial, and utility applications. Additionally, they shield equipment from electromagnetic (EMI) and radio frequency (RF) interference.
  • Our industrial design and mechanical team designs custom enclosures for consumer, industrial, and power utility applications.
  • In addition to developing the look and feel of a unique custom enclosure, our industrial design projects also include mechanical design and manufacturability testing. We consider every element of the project, including the style and aesthetic as well as the technological concerns.

Learn more about our design considerations by selecting any of the items below.

Water and dust can cause and accelerate the deterioration and malfunction of electric and electronic equipment. There are specific ingress protection (IP) ratings for enclosures that are designed to protect against the ingress of solid and liquid particles. Depending on your product’s application, our designs offer varying levels of sealing effectiveness against intrusion from tools, dirt, dust, moisture, water splashes, submersions, and jets.

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Thermal analysis is one of the most important design techniques during the design and development of compact, power-efficient electronics systems. This analysis provides insight into the system’s cooling requirements, enhances product reliability, and helps avoid premature component failure, over-design and under-design issues, and ensure that all components operate within acceptable thermal limits. We offer pre-compliance testing services that analyze the impact of temperature cycling on your product performance.

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Drop testing is a design consideration of how the product will handle dropping and repeated impacts from handling, shipping, user interaction, and other factors. Proper design techniques can identify potential structural and mechanical weaknesses that may otherwise not be detected by vibration and shock tests. Ultimately, this enables the identification of warranties from poor packaging and handling.

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Whether your product is subject to experiencing rough terrain, intermittent or continuous vibrations, or requires to withstand seismic events, a ruggedized design is a primary design criterion to minimize negative effects due to shock and vibration. We offer pre-compliance testing services that analyze the impact of shock and vibrations on your product performance.

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Design for temperature resistance provides optimal sealing for use in extreme temperature ranges, depending on your product application. This resistance helps maintain product integrity irrespective of the temperature conditions. We offer pre-compliance testing services that analyze the impact of temperature cycling on your product performance.

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User-friendliness and ergonomics are the primary factors that are considered when designing enclosures for consumer applications. It is important to use fabrics and materials that are both non-reactive and antimicrobial for wearable devices that come into direct contact with the skin and sweat for an extended period of time. This material selection ensures the safety and health of the user.

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It is crucial to consider the conditions of sunlight, rain, extreme temperature changes, or snow when designing an enclosure or choosing materials for your product. Designs subject to harsh conditions typically require metal enclosures, however, UV protection and coatings can be added to plastic to increase their durability. We offer pre-compliance testing services that analyze the impact of industrial environmental elements on your product performance.

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It is essential that security and access control products are rugged, discrete, and capable of operating in a variety of operational environments. Our designs utilize tamper-indicating technologies to ensure the integrity of your product, equipment, and materials.

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Design Process

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Step 1. Requirements

Product requirements, such as IP rating, EMI shielding, environment, use case, etc., are gathered.

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Step 2. Sketches

5-10 hand sketches of 2D/3D photorealistic images in a variety of colors and textures.

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Step 3. 3D Modeling

3D model generated for “Top 3” sketches.

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Step 4. Finalize Model

2D drawing and enhanced 3D model generated for selected enclosure.

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Step 5. Prototyping

3D printing enclosure to evaluate aesthetics and verify mechanical measurements.

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Step 6. DFM

Design for manufacturability; prepare manufacturing package for production build.

Our mechanical and industrial designers are with you every step of the way, from creating the concept to addressing any manufacturing concerns, resolving technical challenges, and post-launch product support.

Material Selection

Our team has a wealth of experience and expertise in the use of all the listed materials below:

Materials

  • Various types of plastics: ABS, ABS+PC, EK, PC, PE, PVC, PMMA, polyamide plastics, etc.
  • Metals: production of enclosure parts from stainless steel, aluminum, and aluminum-magnesium alloys, using multiple technologies (stamping, molding, milling, extrusion molding)
  • Injection molded plastics
  • Over-molded plastics
  • Thermoformed plastics
  • Rotomolded plastics
  • Sheet metal and weldments
  • Cast metals and plastics
  • 3D-printed plastics
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Capabilities and Application

  • IP-rated design (IP55, IP66, IP67, IP68)
  • MIL-STD (810G and other)
  • Heat management
  • Electronics mounting
  • Ergonomic and human interface consideration
  • Light pipe design
  • Button design and placement
  • Design for manufacture and assembly
  • Consumer Products
  • Industrial Products
  • Industrial Equipment and Instruments
  • IoT Devices
  • Medical Devices
  • Defense/Military Products
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