Enclosure manufacturing is the process of designing and producing housings that protect and package your electronics. A well-designed enclosure is more than a box — it provides durability, safety, thermal management, and user accessibility while giving your product a professional finish.
What is Enclosure Manufacturing?
Enclosures are custom or standardized shells that house PCBs and assemblies. They can be made from plastic, metal, or composite materials and may include cutouts, mounts, gaskets, cooling features, and branding. The right enclosure ensures your device is functional, safe, and appealing for end users.
Essential Factors to Consider
- Material Choice –
- Plastic (ABS, polycarbonate): cost-effective, lightweight, good for consumer devices.
- Metal (aluminum, steel): strong, EMI shielding, suitable for industrial/automotive.
- Die-cast alloys: durable with good detail, higher tooling costs.
- Manufacturing Process –
- Injection Molding: high upfront tooling, lowest per-unit cost at scale.
- CNC Machining: precise, flexible for low-volume runs.
- Sheet Metal Fabrication: fast, strong, scalable.
- 3D Printing: excellent for rapid prototypes.
- Design Features – Proper mounting bosses, ventilation, cable entry points, and seals (IP rating for water/dust protection).
- Certifications – UL flammability ratings, IP protection levels, or industry-specific standards.
How to Choose the Right Manufacturer
- Capabilities: Match the process to your needs — CNC for prototyping, injection molding for mass production.
- Tooling Investment: Some methods require expensive molds, so balance upfront cost vs. long-term volume.
- Finishing Options: Consider painting, powder coating, anodizing, or custom branding.
- Location: Overseas manufacturers often reduce unit cost, while local vendors may provide quicker iterations.
- Design Support: Some vendors offer CAD/DfM services to optimize your enclosure before cutting or molding.
Typical Price Points
- 3D Printing / CNC (low-volume prototypes): $50–$500 per unit depending on size and material.
- Sheet Metal Fabrication (small batch): $20–$100 per enclosure.
- Injection Molding (mass production):
- Tooling cost: $5,000–$20,000 (one-time).
- Per-unit cost: as low as $1–$10 at scale.
Tip: Start with CNC or 3D-printed prototypes before committing to expensive molds for injection molding.
Finding the Best Fit
- For prototyping: rapid CNC shops and 3D printing services are ideal.
- For low-medium volumes: sheet metal or CNC machining balances cost and flexibility.
- For mass production: injection molding is unbeatable for consistency and per-unit price.