Prototype
1–10 units
- Functional validation
- Quick iterations
- Testing before larger commitment
- Delivery: days
Additive Manufacturing of Enclosures
Functional enclosures for electronics — from prototype to production series — without tooling costs, with engineering that understands what goes inside the box.
When to use additive manufacturing for enclosures
Additive manufacturing (3D printing) makes sense for electronic enclosures when:
- Volume doesn't justify tooling: injection molds are expensive and only pay off at thousands of units
- Custom geometry: specific cutouts, unusual formats, board-tailored housings
- Quick iterations: design changes without retooling
- Integrated functional elements: guides, supports, heat dissipation, cable routing
- Low initial investment: no tooling cost, you pay per produced unit
Volume Ranges
Pilot / Small series
10–500 units
- Pre-series production
- Controlled deployments
- Niche products
- Delivery: 1–4 weeks
Series production
500–5000+ units
- Continuous production
- Optimized processes
- Unit cost as a factor
- Scheduled deliveries
Above 5000 units, we evaluate whether additive manufacturing is still the best option or if transitioning to tooling makes sense.
Technical Aspects
Materials
- ABS, ASA, PETG: general use, good impact resistance
- Nylon (PA): abrasion resistance, flexibility
- PC (polycarbonate): high temperature, flame resistance
- Specialty compounds: UV resistance, static dissipation, specific colors
Finishes and Post-processing
- Chemical or mechanical smoothing
- Painting and texturing
- Metal inserts (heat-set or press-fit)
- Laser engraving, silk-screen printing
IP Protection
We design enclosures with real IP protection — not just "splash-resistant". Gasket integration, tested closures, documentation of achieved protection level.
When NOT to use additive manufacturing
We are honest about the limitations:
- Very high volumes: above 5–10k units, injection may be more economical
- Very tight tolerances: if you need precision below 0.1mm, machining may be better
- Specific materials: some resins and compounds are only available for injection
- Cosmetic surface: if the consumer finish is critical, injection or machining has advantages
When additive manufacturing is not the best option, we help evaluate alternatives.
Integration with Automation Projects
Ioseph Engenium designs enclosures with deep understanding of what goes inside:
- Boards and controllers: precisely positioned mountings, thermal management
- Connectors and cables: cutouts, glands, service access
- Industrial environment: consideration of vibration, temperature, humidity
- Maintenance: practical access design for repairs and updates
This is especially useful for clients who are also doing automation or gateway projects with us — a single point of contact for enclosure + electronics + firmware.
Cost Simulator: AM vs Injection
Want to understand at which volume each process makes sense? Use our conceptual simulator to compare costs between additive manufacturing and injection molding.
- Enter weight, dimensions and part complexity
- Visualize total cost curves vs quantity
- Identify the approximate break-even point
Need a custom enclosure?
Send a brief description of the project — board dimensions, intended quantity, special requirements — and we'll do an initial feasibility analysis.