The Problem
A hardware startup needed 20 functional enclosures for an upcoming pilot deployment and critical investor demos. They couldn't justify the high cost and long lead time of injection molding for such a small batch, but they still needed parts that looked professional and functioned perfectly in the field.
The Challenge
Creating pilot-ready parts without injection molding tooling presented several hurdles:
The Solution
We used advanced 3D printing paired with expert post-processing to simulate injection-molded quality.
- ✓Material Selection: Opted for durable ABS 3D printing to provide the necessary impact and thermal resistance for field use.
- ✓Design Iteration: Designed a reliable snap-fit assembly and optimized the internal layout to securely hold the PCBs and batteries.
- ✓Post-Processing: Applied hand sanding followed by vapor smoothing to eliminate layer lines and achieve a professional, glossy finish.
- ✓Functional Sealing: Improved weather sealing through minor design tweaks to the mating lips of the enclosure halves.
The Outcome
We delivered all 20 units in just 6 days. The vapor smoothing process achieved a demo-ready finish that impressed investors, while the redesigned snap-fits reduced assembly time by ~30%. The devices were successfully deployed in a pilot test across 3 separate locations, functioning flawlessly in outdoor conditions.