How customized enclosures add value to your design?
Enclosure developers have a lot of common ground: Customers seldom buy their items off the shelf. Instead, consumers frequently request that enclosure manufacturers make minor alterations to the original design. As a result of the supplier’s efforts, the client gained a distinct edge over the competition. Customers frequently request that their enclosures’ typical features be customized, such as switching to ventilation cooling from conduction cooling or adding an extra door.
The enclosure is a value-added COTS rather than a conventional COTS. It means that the equipment featured in the catalog is available in various slightly altered forms based on the preferences and requirements of the individual client.
Custom-made products are often more costly and less reliable than those purchased off the shelf. It is because the product can be mass-produced in a short period on a tight budget. Customer-specific modifications to commercial-off-the-shelf products (COTS) are known as “modified OTS” (MOTS). Once a COT is amended, the consumer is responsible for managing the product’s modifications.
For many major corporations, obtaining off-the-the-shelf items has become a requirement. COTS products are used in large organizations since they are a low-risk investment and provide a wide range of features. As a result, the COTS product market has grown.
Let’s take a look at the scenario to have a better grasp of what’s going on.
An electronic device has been developed, and you have determined that you can take that product to the next level with a few modifications and new insights into the target market. Therefore, in a state of euphoria, you decide to tweak your electronics and add features, some of which may necessitate using a bespoke or customized housing rather than the diecast box you purchased online.
You hire an industrial designer to assist you in creating a custom enclosure that exudes professionalism. They say that a simple bespoke enclosure will cost upwards of tens of thousands of dollars to design and build. Dejected, you question the project’s viability because of the high expense.
It’s a regular occurrence in the field of electrical design. With so many possibilities available, making a custom enclosure may be difficult and irritating. This guide provides a list of considerations that can assist reduce time and cost and maximizing value in creating a custom enclosure:
- Thoughts on Enclosure Design
- Customizable rather than Custom Design
- Tooling or No Tooling
Before delving into the specifics of the three factors mentioned above, you must understand the distinctions between modified and custom enclosures.
UNDERSTANDING CUSTOM & MODIFIED ENCLOSURES
Custom electronic enclosures are typically developed from inception to completion and are used when a pre-existing product fails to meet a user’s needs. For example, the enclosure can have a specific visual appearance and the dimensions and functionality needed.
Prepping how PCBs will be mounted, where power supplies are to be located, tolerance and formulating angles, and heat dissipation are just a few things among a long list to keep in mind. YONGUBOX can help you avoid costly design blunders by drawing on our expertise.
A conventional product is typically the motivation for a custom enclosure. It means that an electronic enclosure that a developer likes may not be what the designer needs. For example, the designer may need an enclosure with a hinged cover on an inventory levels enclosure that only has screw-down covers. For example, adding UV protection to an interior enclosure is a regular request for custom plastic formulations. Because a significant portion of the engineering has already been worked out, developing a bespoke design based on a standard enclosure offers a quick and economical solution.
If a bespoke enclosure can be designed to be as similar as possible to the standard enclosure offered by a manufacturer, it will likely be more cost-effective.
Modified enclosures are an essential part of every custom enclosure discussion. Adding features or functionalities to a primary, off-the-shelf enclosure is possible using the necessary gear or tools. Cutting holes, slots, or cuts is the most popular way to modify enclosures. For most enclosures, unique cut-outs on the front panel are required to accommodate screens, switchgear and knobs, communication wires, and power cables to enable power and data to be input and output.
A specific EMI-protection gasket is one of the most practical additions. A few of these alterations, including automatic printing and distinctive color schemes, are meant to help the final product stand out in the marketplace.
Pre-assembly isn’t a change, but it’s in the same vein. It is possible to have a rack sent with a customized set of shelves, fan trays, cable management systems, and chassis. Accessories like standoffs, interior panels, and vents can be pre-installed in electronic enclosures.
A modified enclosure does not alter the basic enclosure construction. It’s common for design engineers to pick a conventional enclosure with modest alterations due to the different prominent families of enclosures available.
Ratings are another factor to consider. If the originating enclosure is created following the standard rating regulations, it is easier to acquire a NEMA or IP rating on a modified enclosure.
CONSIDERATIONS FOR CUSTOM OR MODIFIED DESIGNS
Thoughts on Enclosure Design
Because the tooling is an expensive investment, your design must be flawless. To minimize the time and money spent on design, it’s critical to be as specific as possible when describing your needs. When you haven’t finished fleshing out your system design, it’s simple to say but difficult to put into action. Here are a few things to keep in mind when designing an enclosure so that you don’t make costly mistakes later on.
Consider how much you’ll need throughout the product’s lifespan. Consider the design’s continuity strategy. Is this a continuous process of revamping with each manufacturing run, or are you planning to build to a maximum amount over time?
The next step is to create a functional specification that ties into the intended characteristics of the enclosure. Consider the following:
- Product and Accessories Dimensions
- NEMA & IP rating
- Power Strips and Switches
- Latches and Locks
- External indicators and displays
- Type of mounting
- Unique functionalities
Decide whether or not the aesthetics are essential. An enclosure’s appearance is often cited as a primary motivation for developing a customized one in the first place. However, certain functionalities can only be implemented in limited ways.
Customizable rather than Custom Design
- If your recurring quantities aren’t in the hundreds of thousands, it may be more logical to look at conventional alternatives that can be adjusted to fit.
- To learn what is and is not possible, speak with enclosure makers.
- Avoid putting too many I/O and connections on the edges.
- As a general rule, select common alternatives and materials, such as standard metals or plastics, if feasible.
It’s possible to include your company’s emblem and colors into the design of a customizable industrial enclosure so that customers are reminded of who you are and what you stand for at all times.
Buyers can quickly identify your items and to ensure that consistent design is essential. Customers often request that we modify an industrial design to match other goods in their fleet. Because you have more pieces with your company’s logo prominently displayed, potential customers are seeing more of your stuff.
Tooling or No Tooling
Although injection molds are costly, the final product has a reasonable cost per unit when produced in bulk. For low-volume injection molding, you should use aluminum tooling, which is significantly less expensive than steel. Tools wear out considerably more rapidly, but they’ll get you up and running faster and for less money. When you’ve finished designing the component in various ways, such as drawings, 3D CAD models, and 3D prints, you’re ready to send it off to an injection molding firm for verification and pricing, pay for tooling, check functionality and appearance, and then put it into production. No matter what, this is a time and money-consuming procedure.
To succeed in the tooling field, one must be an excellent designer of injection-molded parts. The aesthetics of your parts will suffer if you don’t strictly adhere to the design rules.
Tools may be costly; thus, plastic or diecast aluminum enclosures made to specific dimensions are standard. Unique characteristics such as extra mounting bases, wall-mounting facilities, card rails, and cuts and holes that transform the enclosure into a complete unit may be efficiently designed into a new tool. The tooling costs can be readily mitigated if the numbers are large enough to allow for a product with a unique appearance or one that fits a specific consumer demand.
For many consumer electronics, generic enclosures are utilized instead of custom-designed ones. As a result, people don’t realize that the enclosure for medical gadgets, industrial tablet computers, and remote controls is not custom-made. Logo-printed and brand-colored enclosures are especially susceptible to this.
YONGUBOX can assist with designing an electronic enclosure and constructing a new enclosure from scratch. The process begins with an application analysis, followed by CAD tools to develop an optimum design for the enclosure.
Designing The Unique Prototype
One of YONGU’s services is Designing a unique prototype. We provide OEM and ODM products. If you want your products to be different from others, we may help you design your prototype’s new structure and appearance.
- Communicate your requirements for the box online
- Design a unique appearance and structure for your prototype
- Modify the design for free until you are satisfied.
- Provide sample service before placing orders in batches, and help you test the aluminum case to ensure that it meets your needs.
YONGUBOX also manufactures customized metal racks, sheet metal enclosures, and custom-molded plastic enclosures. Almost any plastic or aluminum enclosure may be formed and welded at our facility, thanks to our state-of-the-art equipment and highly trained employees. Plastic and aluminum are the most preferred materials for customized industrial enclosures.
Engineering The Best Solutions
One of the services YONGU offers is engineering the most effective solutions. We can materialize your concepts and ideas into a functioning prototype or a batch of items.
- If you provide us with your 3D model, CAD file, and hand-drawn sketch, we will be able to make it in Solidworks, manage it, and confirm it with you.
- We make our existing items’ 3D, and CAD design files available so you can modify them.
- All you need to do is provide us with a concept, and we will handle everything else.
- We provide a comprehensive collection of workable solutions for PCB boards, which are the internal structural portions of electronic devices.
The aim of YONGUBOX is to parameterize the system design and operation parameters to employ Multi-Disciplinary Optimization methods to optimize the system according to the requirements you have specified for a bespoke product.
Processing The High-Quality Products
One of the services that YONGU provides is the processing of high-quality boxes. Instead of focusing on developing frictionless technology, distinctively allow precise supply chains. You will be provided with an aluminum enclosure of high precision and quality.
- Answers to your questions on the manufacturing process
- Fabrication of aluminum boxes and goods using CNC equipment
- Designing, constructing, and testing with the most incredible possible quality
- Providing the most satisfactory outcomes at a fair price
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