Where to get 100 enclosure cases made ?

Bean · 2013-09-29 07:48

I have a project that requires and enclosure case.
I have a 3D model and have printed it on my 3D printer.
Problem is I'm going to need at least 100 of each half and I don't look forward to printing them myself.

Does anyone know of a company that can made them from my 3D model for a decent price ?

Each half is about 4"Lx3"Wx0.75"H the material doesn't really matter as long as it can survive a 6 foot drop without damage.

Thanks,

Bean

Ron Czapala · 2013-09-29 08:07

I don't know about cheap or whether they can use your 3D model, but they may be able to customize one of their products

https://www.hammfg.com/dci/mods

When a standard cabinet isn’t exactly what you need, Hammond can modify our designs for the ideal cabinet solution. Should you need some assistance specifying your enclosure, our experienced sales and design professionals will share their expertise to help determine which enclosure would best fit your needs. Unlike costly custom projects, Hammond offers five different options of tweaking existing cabinet designs to accomdate your needs.
Here’s a list of just some of the common modifications we can do for you:
Special Paint Colors

Silk Screening

Non-Standard Sizes

Alternate Material Construction

Cutouts

Punched Holes

Louvers

Tapped Holes

Pre-Installed Accessories

Alternate Handles

Add, Move or Delete Studs

Hinge Changes

and more...

LoopyByteloose · 2013-09-29 08:27

Rather than 3-D printing, I'd consider laser cutting of acrylic panels or another appropriate sheet plastic.

You have two rather large surfaces that can be 'sandwiched' with the board inbetween via standoffs. The other 4 side can just be keyed into the top and bottom. The ends can all be either butt glued with conventional acrylic glue technique or mechanically keyed somehow.

For build a box, it is difficult to be sheet materials for being cost-effective. Buying spools and spools of 3-D plastic may really cost a lot more.

dgately · 2013-09-29 09:21

At the bottom of this page, there are a few links to 3D print services. I'm not sure if they require using AutoDesk's tools, so you'll need to investigate your options...

http://www.123dapp.com/about3D

dgately

GordonMcComb · 2013-09-29 10:25

Is there something unique about your enclosure design that would prohibit you from taking a standard plastic enclosure, and having any holes and other openings routed? That's generally cheaper and faster, and there are many local businesses that can do that kind of work.

WBA Consulting · 2013-09-29 12:25

Several of my customers are using Protolabs for exactly that. Not necessarily cheap, but effective. I will also second Gordon's suggestion. Poly case has a large selection of cases and they do machining and silkscreening in house. At quantities of 100, the setup costs get absorbed well.

Bean · 2013-09-29 13:29

Thanks for the suggestions, I'll look into them.

Bean

max72 · 2013-09-29 13:31

protolab's protomold is a nice place to check.
You can upload the 3d model and in short time get an evaluation of feasibility, and price, choosing material and quantity. 100 are probably on the low side, but worth a (free) check.
You could also check, still for free, shapeways.
Massimo

Phil Pilgrim (PhiPi) · 2013-09-29 14:03

Bean,

Can you post your STL file? Let's see exactly what we're looking at.

-Phil

W9GFO · 2013-09-29 14:13

I designed and have made several hundred of these cases;

I don't have any photos that I took myself so this one will have to do for now. It is 100% laser cut and assembles with eight screws.

Phil Pilgrim (PhiPi) · 2013-09-29 14:20

Rich,

That is quite nice! And 'very clever the way you handled the stacked laminations.

-Phil

max72 · 2013-09-29 14:25

great looking box!
How did you manage to screw it together? Towers?
Massimo

W9GFO · 2013-09-29 15:04

Thanks!

Here is a cutaway view;

Phil Pilgrim (PhiPi) · 2013-09-29 15:16

Radiation detector / Geiger counter?

-Phil

Ron Czapala · 2013-09-29 15:19

Phil Pilgrim (PhiPi) wrote: »

Radiation detector / Geiger counter?

-Phil

Radiation detector - http://excelphysics.com/collections/frontpage/products/apoc-basic-kit

Looks neat!

GordonMcComb · 2013-09-29 15:37

This is an extremely well done product all the way around. The instructions page alone should be used as an example of how it should be done.

mindrobots · 2013-09-29 17:03

Bean,

Try and get hold of Jim Fouch (forum member in PA, I believe) He's been to a number of Jeff's Expos. He's launching a online service to create laser cut cases. He may have some ideas or be able to help you out.

I'm not sure how well any of the laser cuttable materials will hold up to a 6 foot drop but Jim may have some ideas.

If I find his contact info, I'll send it to you in a PM but a PM to Jim might work too.

W9GFO · 2013-09-29 19:15

mindrobots wrote: »

I'm not sure how well any of the laser cuttable materials will hold up to a 6 foot drop...

Cast acrylic, the only type I use, is significantly more durable and much less brittle than the standard extruded like what you would get at a home improvement store. Of course it depends upon what the case is hitting after falling 6 ft. A 6ft drop onto a wood or carpeted floor I am sure would be fine. Dropping onto concrete would probably result in at least a chip if it doesn't land flat - but I think that asking an electronic device to survive a 6ft fall onto concrete is a little much unless it is designed for extreme service.

Bean · 2013-09-30 04:19

Phil Pilgrim (PhiPi) wrote: »

Bean,

Can you post your STL file? Let's see exactly what we're looking at.

-Phil

Here is one half, the other is very similar.

Bean

Bean · 2013-09-30 04:20

W9GFO wrote: »

I designed and have made several hundred of these cases;

I don't have any photos that I took myself so this one will have to do for now. It is 100% laser cut and assembles with eight screws.

Wow, That is great.

Could you give me an idea about how much ($) these cost is I wanted 100 of them ? You can send me a PM is you want.

Bean

W9GFO · 2013-09-30 05:26

PM sent.
PM sent.

LoopyByteloose · 2013-09-30 07:25

Acrylic plastic in thicker sheets is actually used to make bullet-proof windows in police stations. So I suspect the drop factor can be resolved by using thicker acrylic.

Ideally, it would be handy if you could use vinyl sheet plastic, but I am uncertain that this will play nice with a laser cutter. And it may be more difficult to source.

max72 · 2013-09-30 08:28

W9GFO wrote: »

Thanks!

Here is a cutaway view;

Thanks.
Great stuff.

jones · 2013-09-30 08:44

Loopy Byteloose wrote: »

Acrylic plastic in thicker sheets is actually used to make bullet-proof windows in police stations.

The plastic used in bulletproof windows is polycarbonate, known most commonly by the brand name Lexan. It can be laser cut (though not very well, apparently), but isn't available in as many colors as acrylic (e.g. http://www.bclaserworks.com/pdf/lasercutpolycarbonate.pdf)

Phil Pilgrim (PhiPi) · 2013-09-30 09:21

Loopy Byteloose wrote:

Ideally, it would be handy if you could use vinyl sheet plastic, but and am uncertain that this will play nice with a laser cutter.

No, you definitely cannot cut vinyl with a laser cutter. Doing so releases chlorine gas, which not only is poisonous but combines with moisture in the air to form HCl. The latter will destroy the laser cutter's electronics in very short order. Most laser manufacturers clearly exclude vinyl cutting from their warranties.

-Phil

WBA Consulting · 2013-09-30 10:27

W9GFO wrote: »

........but I think that asking an electronic device to survive a 6ft fall onto concrete is a little much unless it is designed for extreme service...........

FYI, surviving a 6 foot drop onto concrete is a pretty common standard for small and/or portable electronics. Cell phones are tested in this manner (by makers and users, LOL). Many of the smaller devices we manufacture at work were put to this test by the designers but they are "normal service" products. One small device that goes into server rooms not only must be able to survive (as in still be functional) a 6 foot drop onto concrete, but the battery door must also remain attached (it's a snap close door, no screws)

LoopyByteloose · 2013-09-30 13:28

It is one thing to have a 2.5 kilo laptop drop from that height (a disaster to most of us), but a unit that weights 100 grams is not going to suffer too much.

In many cases, the battery is the most mass in the object and if that is very secure... not much is going to suffer.

One could laminate neoprene to the corners and sides. We need some flubber.

LoopyByteloose · 2013-09-30 13:54

Poly-carbonate looks very attractive. If you can laser cut your project, maybe you can polish the edges with polishing compound (comes from automotive supply house) to get a clean look.

Phil Pilgrim (PhiPi) · 2013-09-30 14:17

Polycarbonate does not laser very cleanly. Secondary operations, like polishing, on 100 units would be prohibitive. Acetal copolymer (like Delrin) lasers cleanly and is very tough. It's not as rigid as Plexiglas, though.

-Phil

WBA Consulting · 2013-09-30 17:16

Phil Pilgrim (PhiPi) wrote: »

..... Acetal copolymer (like Delrin) lasers cleanly and is very tough.....

+1 Delrin is my material of choice on the laser when quality results matter. It has a good match of price, quality of cut, and durability. When thin ribs are cut into a piece, you can create flexible joints and living hinges.

T Chap · 2013-09-30 18:55

Bean, does this box have any negatives or side action requirements? If not then for a few grand you can get both parts on one mold probably. Then the parts are cheap after the initial mold construction.

Where to get 100 enclosure cases made ?

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