Project Overview
A robotics startup required custom enclosures for their sensor array controllers, needing rapid iteration as their electronics evolved. The housing demanded integrated thermal management, secure mounting points, and protection against industrial environments.
Challenge
The client’s electronics generated significant heat during operation, and off-the-shelf enclosures couldn’t accommodate their unique PCB geometry. They needed custom cooling channels, cable routing, and mounting features—all while maintaining a professional appearance for their B2B customers.
Solution
We developed a custom FDM-printed enclosure in PETG featuring:
- Integrated heat sink fins increasing surface area by 40%
- Internal cable management channels
- Snap-fit assembly with captive hardware
- IP54-rated gasket grooves
- Modular design for field serviceability
### Technical Specifications
| Parameter | Value |
|———–|——-|
| Material | PETG |
| Technology | FDM |
| Wall Thickness | 3mm |
| Heat Resistance | 73°C continuous |
| IP Rating | IP54 (with gaskets) |
| Assembly | Tool-free snap-fit |
Results
- Improved thermal performance vs the aluminum enclosure
- Assembly time dramatically reduced
- Client proceeded to a production run
- Design iterated 3 times in single week
Client Feedback
> “The integrated cooling channels work better than we expected. Our field technicians love the tool-free assembly—it’s cut our service time dramatically.”
Industry: Robotics / Industrial
Technology: FDM 3D Printing
Location: Montreal, QC
