Case study

3D-printed technical enclosure: case study

This part was 3D printed to meet a specific need with real mechanical and usage constraints — assembly, fastening, and integration validation before heavier industrialisation.

The initial need

Frame the requirement first: without a clear need, a prototype is a demo — not a decision tool.

Context

Compact equipment needing an enclosure for board and connectors, with footprint and fastening constraints on an existing plate.

Problem

Validate geometry, cable routing, and assembly clearance without committing immediately to a mould or costly machining.

Constraints

Resistance to repeated handling, standard screws, moderate operating temperature, presentable finish for a client demo.

What we did

Material choice

PETG: good compromise for a handled part, fairly robust, better moisture behaviour than PLA for extended use. A first iteration can be PLA to iterate faster on shape.

Design

Walls sized for screwing, fillets at corners to limit stress concentration, assembly clearances planned in the 3D model.

Method

FDM print orientation to stiffen the enclosure, infill and thickness suited to clamping; tweaks after first print before the “functional” version.

Material detail: PETG sheet.

Outcome

  • Performance: enclosure rigid enough for component mounting and repeated wiring.
  • Real use: integration tests on the target plate, clearance and access validated.
  • Decision: informed next step (revise a few dimensions, change process, or small batch depending on volume).

Materials used

Main filament for this case: PETG — see the sheet for limits, settings, and uses.

Open PETG sheet

Project visuals

Photos of the final result and assembly details to add in the gallery below when assets are available.

Photo of assembled enclosure — to add
Overview
Fastening / interior detail — to add
Technical detail

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