3D-Printed Enclosures

Table of Contents

3D-Printed Enclosures

3D Printed Enclosures

Introduction to 3D-Printed Enclosures

3D-printed enclosures provide significant benefits due to their high level of customizability. They can be designed to meet specific requirements, such as complex geometries, intricate patterns, or particular shapes and sizes. Another crucial benefit of this technology is rapid prototyping. Designers can create and test designs quickly, produce multiple iterations, and identify potential issues in the design early in the process, which reduces the overall time and cost in the product development cycle. Rapid prototyping also enables faster time-to-market for the final product.

Additionally, 3D-printed enclosures offer high accuracy and precision, critical for ensuring the final product’s high quality. With tolerances as small as a few microns, this technology can produce parts with unmatched accuracy and precision, ensuring that the final product meets all required specifications. Overall, 3D-printed enclosures offer an affordable, customizable, and precise solution for various applications.

3D-Printed Enclosure Applications

Enclosures are frequently used to protect electrical components. They are also commonly found in automotive and consumer products, ranging from disposable clamshells for deli products to storage cases for earbuds. Enclosures make it easier to transport these products, and they can also house multiple components in a single space, thereby preventing customers from losing any parts.

Designing 3D-Printed Enclosures

When designing 3D-printed enclosures for industrial use, it is essential to consider the placement of components and follow recommendations to create a strong structure.

3D Printed Enclosure Bosses

When threaded fasteners are needed, include bosses around the holes to reduce bulging and distortion.  For best design practices, ensure the diameter hole is also the thickness of the wall surrounding it.  For example, for an 3/16th screw, you would need a 0.2 in (0.5 mm) width wall around the threaded hole.

3d printed enclosures - Bosses
Internal Component Spacing

After considering the locations of the components, provide a 0.02 in (0.5 mm) clearance around the internal component. These clearances will account for technology tolerances, shrinkage, and distortion.

Connecting Parts of 3D Printed Enclsures

Living Hinges

Living hinges are flexible joints used in various applications to consolidate two parts of an enclosure. These hinges are made from the same material as the parts they connect and are designed to bend repeatedly without breaking. Using a living hinge can eliminate the need for additional hardware, such as nuts and bolts or rivets, which can reduce production costs. In addition to being cost-effective, living hinges are also lightweight and can be used to create a seamless, aesthetically pleasing design. They are commonly used in producing enclosures and casings for electronic devices, as well as in packaging and other industries. Overall, living hinges are a reliable and efficient way to connect two parts of an enclosure while maintaining a consistent and secure seal.

Snap-Fits

Snap-fit interlocking features are commonly used in various products, including enclosures, carabiners, clips, and other parts that require a connection. While designing snap-fits, it is essential to consider the arm’s thickness, the tapering from the root to the hook, and the filleting of the root to prevent snapping. The build direction of snap-fits is also crucial. The best practice is to build the snap-fit in the same direction as the image to the right.

Threaded Fasteners

Fasteners such as screws, bolts, and nuts are widely used in various enclosures to fasten two or more pieces together securely. They are an efficient and effective way to join parts as they offer solid and reliable connections. Screws, in particular, are a popular fastening option as they are easy to install and remove, making them ideal for frequent disassemblies and reassemblies. Additionally, screws come in different sizes, lengths, and materials, which makes them versatile and adaptable to a wide range of enclosure applications.

3d printed enclosures - 3D-Printed Threads and Tapped Holes
3D Printed Enclosure Holes

Drilling clearance holes after printing is recommended for the most accurate results. However, if you need to print the holes, it is essential to remember that you should add 0.0787 in (2 mm) to the diameter of the hole to ensure proper clearance. Clearance holes are intended to allow for the smooth insertion of screws or bolts without causing any damage to the printed object.

On the other hand, if you plan to create self-tapping holes, you should subtract 0.0787 in (2 mm) from the diameter. Self-tapping holes are designed to develop their threads as they are being inserted, which is why the diameter needs to be slightly smaller than the screw or bolt being used.

It is important to note that these adjustments are necessary to ensure that the holes fit the specific screws or bolts you are using, and it is recommended to test fit before final assembly. Additionally, using the correct drill bit size is crucial to avoid any damage to the printed object.

Port Clearance

Ensuring a 0.0787 in (2 mm) clearance around the ports is essential when assembling the components. This will prevent any potential damage to the ports during the assembly process. Once the build is complete, the input ports can be carefully super-glued into place. This will secure them in position and prevent any accidental movement or dislodgement. It is recommended to exercise caution while applying the glue to avoid any spillage or mess around the ports.

3d printed enclosures - Port Clearance
Radii and Fillets

It is essential to design enclosures that can withstand a variety of stresses. One way to reduce the stresses on an enclosure is by adding radii and fillets at the corners and edges. These rounded features help distribute the stresses evenly throughout the structure, preventing any point from bearing too much weight. This, in turn, can increase the overall strength and durability of the enclosure. Additionally, radii and fillets can improve the design’s aesthetics by softening sharp corners and creating a more uniform appearance.

Walls

To ensure a successful industrial 3D printing process, it is essential to maintain a minimum wall thickness of 0.0787 in (2 mm). Although wall uniformity is not a requirement for industrial 3D printing, it is highly recommended as it can enhance the structural integrity of the final product. If the part is intended for injection molding in the future, wall uniformity is an absolute must. This is because injection molding requires consistent wall thickness throughout the part to prevent defects and ensure the proper functioning of the finished product. Therefore, it is essential to keep in mind the end goal of the part before deciding on the wall uniformity during the 3D printing process.

CNC Machined Enclosures

CNC machining is a manufacturing process that can create parts directly from a CAD file. It is a subtractive process that takes a solid block of metal or plastic and removes material to create a desired shape. One of the significant benefits of CNC machining is that it is highly repeatable. Once an enclosure is made, we can produce the same part thousands of times. CNC machining can also create complex, asymmetrical structures and smooth curves that may not be possible with other manufacturing methods. However, it is slower and more expensive than sheet metal forming and 3D printing.

Sheet Metal Enclosures

Enclosures are commonly made using sheet metal forming. This process involves shaping sheet metal through mechanical or hydraulic means to create a desired form. Enclosures made through this method are known for being affordable, durable, and easy to produce. They are ideal for housing electronic equipment and machinery components. Materials like aluminum, stainless steel, and steel can be used to make enclosures. These materials offer unique advantages based on the application’s intended use and specific requirements. Sheet metal forming is a reliable and cost-effective solution that provides flexibility regarding material options and design possibilities.

Work With Prototek

Prototek is a comprehensive digital manufacturing service provider. Whether you have an enclosure project, we have a variety of solutions that can cater to your needs, including additive manufacturing, CNC machining, and sheet metal fabrication. We are also capable of scaling from prototyping and small production runs to larger production runs with the help of cast urethane and injection molding.

We would enjoy discussing your project to see if we’d be a good fit! You can contact us or get a quote!

The content on this blog post is for informational purposes only. Prototek does not make any declaration or guarantee, whether expressed or implied, regarding the information’s accuracy, completeness, or validity. Any performance parameters, geometric tolerances, specific design features, quality and types of materials, or processes should not be assumed to represent what will be delivered by third-party suppliers or manufacturers through our network. It’s crucial to note that buyers seeking quotes for parts are responsible for defining the specific requirements for their project.

Standard Drill Bit Sizes

Drill Size

Imperial

Metric

#107

0.0019 in

0.0483 mm

0.05 mm

0.0020 in

0.0500 mm

#106

0.0023 in

0.0584 mm

#105

0.0027 in

0.0686 mm

#104

0.0031 in

0.0787 mm

#103

0.0035 in

0.0889 mm

#102

0.0039 in

0.0991 mm

0.1 mm

0.0039 in

0.1000 mm

#101

0.0043 in

0.1092 mm

#100

0.0047 in

0.1194 mm

#99

0.0051 in

0.1295 mm

#98

0.0055 in

0.1397 mm

#97

0.0059 in

0.1499 mm

#96

0.0063 in

0.1600 mm

#95

0.0067 in

0.1702 mm

#94

0.0071 in

0.1803 mm

#93

0.0075 in

0.1905 mm

0.2 mm

0.0079 in

0.2000 mm

#92

0.0079 in

0.2007 mm

#91

0.0083 in

0.2108 mm

#90

0.0087 in

0.2210 mm

#89

0.0091 in

0.2311 mm

#88

0.0095 in

0.2413 mm

#87

0.0100 in

0.2540 mm

#86

0.0105 in

0.2667 mm

#85

0.0110 in

0.2794 mm

#84

0.0115 in

0.2921 mm

0.3 mm

0.0118 in

0.3000 mm

#83

0.0120 in

0.3048 mm

#82

0.0125 in

0.3175 mm

#81

0.0130 in

0.3302 mm

#80

0.0135 in

0.3429 mm

#79

0.0145 in

0.3680 mm

1/64 in

0.0156 in

0.3969 mm

0.4 mm

0.0158 in

0.4000 mm

#78

0.0160 in

0.4064 mm

#77

0.0180 in

0.4572 mm

0.5 mm

0.0197 in

0.5000 mm

#76

0.0200 in

0.5080 mm

#75

0.0210 in

0.5334 mm

#74

0.0225 in

0.5715 mm

0.6 mm

0.0236 in

0.6000 mm

#73

0.0240 in

0.6069 mm

#72

0.0250 in

0.6350 mm

#71

0.0260 in

0.6604 mm

0.7 mm

0.0276 in

0.7000 mm

#70

0.0280 in

0.7112 mm

#69

0.0292 in

0.7417 mm

#68

0.0310 in

0.7874 mm

1/32 in

0.0313 in

0.7938 mm

0.8 mm

0.0315 in

0.8000 mm

#67

0.0320 in

0.8128 mm

#66

0.0330 in

0.8382 mm

#65

0.0350 in

0.8890 mm

0.9 mm

0.0354 in

0.9000 mm

#64

0.0360 in

0.9144 mm

#63

0.0370 in

0.9398 mm

#62

0.0380 in

0.9652 mm

#61

0.0390 in

0.9906 mm

1 mm

0.0394 in

1.0000 mm

#60

0.0400 in

1.0160 mm

#59

0.0410 in

1.0414 mm

#58

0.0420 in

1.0668 mm

#57

0.0430 in

1.0922 mm

1.1 mm

0.0433 in

1.1000 mm

#56

0.0465 in

1.1811 mm

3/64 in

0.0469 in

1.1906 mm

1.2 mm

0.0472 in

1.2000 mm

1.3 mm

0.0512 in

1.3000 mm

#55

0.0520 in

1.3208 mm

#54

0.0550 in

1.3970 mm

1.4 mm

0.0551 in

1.4000 mm

1.5 mm

0.0591 in

1.5000 mm

#53

0.0595 in

1.5113 mm

1/16 in

0.0625 in

1.5875 mm

1.6 mm

0.0630 in

1.6000 mm

#52

0.0635 in

1.6129 mm

1.7 mm

0.0669 in

1.7000 mm

#51

0.0670 in

1.7018 mm

#50

0.0700 in

1.7780 mm

1.8 mm

0.0709 in

1.8000 mm

#49

0.0730 in

1.8542 mm

1.9 mm

0.0748 in

1.9000 mm

#48

0.0760 in

1.9304 mm

5/64 in

0.0781 in

1.9844 mm

#47

0.0785 in

1.9939 mm

2 mm

0.0787 in

2.0000 mm

#46

0.0810 in

2.0574 mm

#45

0.0820 in

2.0828 mm

2.1 mm

0.0827 in

2.1000 mm

#44

0.0860 in

2.1844 mm

2.2 mm

0.0866 in

2.2000 mm

#43

0.0890 in

2.2606 mm

2.3 mm

0.0906 in

2.3000 mm

#42

0.0935 in

2.3749 mm

3/32 in

0.0938 in

2.3813 mm

2.4 mm

0.0945 in

2.4000 mm

#41

0.0960 in

2.4384 mm

#40

0.0980 in

2.4892 mm

2.5 mm

0.0984 in

2.5000 mm

#39

0.0995 in

2.5273 mm

#38

0.1015 in

2.5781 mm

2.6 mm

0.1024 in

2.6000 mm

#37

0.1040 in

2.6416 mm

2.7 mm

0.1063 in

2.7000 mm

#36

0.1065 in

2.7051 mm

7/64 in

0.1094 in

2.7781 mm

#35

0.1100 in

2.7940 mm

2.8 mm

0.1102 in

2.8000 mm

#34

0.1110 in

2.8194 mm

#33

0.1130 in

2.8702 mm

2.9 mm

0.1142 in

2.9000 mm

#32 

0.1160 in

2.9464 mm

3 mm

0.1181 in

3.0000 mm

3.1 mm

0.1221 in

3.1000 mm

1/8 in

0.1250 in

3.1750 mm

3.2 mm

0.1260 in

3.2000 mm

#30

0.1285 in

3.2639 mm

3.3 mm

0.1299 in

3.3000 mm

3.4 mm

0.1339 in

3.4000 mm

#29

0.1360 in

3.4544 mm

9/64 in

0.1406 in

3.5719 mm

5/32 in

0.1563 in

3.9688 mm

11/64 in

0.1719 in

4.3656 mm

3/16 in

0.1875 in

4.7625 mm

13/64 in

0.2031 in

5.1594 mm

7/32 in

0.2188 in

5.5563 mm

15/64 in

0.2344 in

5.9531 mm

1/4 in

0.2500 in

6.3500 mm

17/64 in

0.2656 in

6.7469 mm

9/32 in

0.2813 in

7.1438 mm

19/64 in

0.2969 in

7.5406 mm

5/16 in

0.3125 in

7.9375 mm

21/64 in

0.3281 in

8.3344 mm

11/32 in

0.3438 in

8.7313 mm

23/64 in

0.3594 in

9.1281 mm

3/8 in

0.3750 in

9.5250 mm

25/64 in

0.3906 in

9.9219 mm

13/32 in

0.4063 in

10.3188 mm

27/64 in

0.4219 in

10.7156 mm

7/16 in

0.4375 in

11.1125 mm

29/64 in

0.4531 in

11.5094 mm

15/32 in

0.4688 in

11.9063 mm

31/64 in

0.4844 in

12.3031 mm

1/2 in

0.5 in

12.700 mm

33/64 in

0.5156 in

13.0969 mm

17/32 in

0.5313 in

13.4938 mm

35/64 in

0.5469 in

13.8906 mm

9/16 in

0.5625 in

14.2875 mm

37/64 in

0.5781 in

14.6844 mm

19/32 in

0.5938 in

15.0813 mm

39/64 in

0.6094 in

15.4781 mm

5/8 in

0.6250 in

15.8750 mm

41/64 in

0.6406 in

16.2719 mm

43/64 in

0.6719 in

17.0656 mm

11/16 in

0.6875 in

17.4625 mm

45/64 in

0.7031 in

17.8594 mm

23/32 in

0.7188 in

18.2563 mm

47/64 in

0.7344 in

18.6531 mm

3/4 in

0.7500 in

19.0500 mm

49/64 in

0.7656 in

19.4469 mm

25/32 in

0.7813 in

19.8438 mm

51/64 in

0.7969 in

20.2406 mm

13/16 in

0.8125 in

20.6375 mm

53/64 in

0.8281 in

21.0344 mm

27/32 in

0.8438 in

21.4313 mm

55/64 in

0.8594 in

21.8281 mm

7/8 in

0.8750 in

22.2250 mm

57/64 in

0.8906 in

22.6219 mm

29/32 in

0.9063 in

23.0188 mm

21/23 in

0.9130 in

23.1913 mm

59/64 in

0.9219 in

23.4156 mm

15/16 in

0.9375 in

23.8125 mm

61/64 in

0.9531 in

24.2094 mm

31/32 in

0.9688 in

24.6063 mm

63/64 in

0.9844 in

25.0031 mm

1 in

1.0000 in

25.4000 mm

1 1/64 in

1.0156 in

25.7969 mm

1 1/32 in

1.0313 in

26.1938 mm

1 3/64 in

1.0469 in

26.5906 mm

1 1/16 in

1.0625 in

26.9875 mm

1 5/64 in

1.0781 in

27.3844 mm

1 3/32 in

1.0938 in

27.7813 mm

1 7/64 in

1.1094 in

28.1781 mm

1 1/8 in

1.1250 in

28.5750 mm

1 9/64 in

1.1406 in

28.9719 mm

1 5/32 in

1.1563 in

29.3688 mm

1 11/64 in

1.1719 in

29.7656 mm

1 3/16 in

1.1875 in

30.1625 mm

1 13/64 in

1.2031 in

30.5594 mm

1 7/32 in

1.2188 in

30.9563 mm

1 15/64 in

1.2344 in

31.3531 mm

1 1/4 in

1.2500 in

31.7500 mm

1 17/64 in

1.2656 in

32.1469 mm

1 9/32 in

1.2813 in

32.5438 mm

1 19/64 in

1.2969 in

32.9406 mm

1 5/16 in

1.3125 in

33.3375 mm

1 21/64 in

1.3281 in

33.7344 mm

1 11/32 in

1.3438 in

34.1313 mm

1 23/64 in

1.3594 in

34.5281 mm

1 3/8 in

1.3750 in

34.9250 mm

1 25/64 in

1.3906 in

35.3219 mm

1 13/32 in

1.4063 in

35.7188 mm

1 27/64 in

1.4219 in

36.1156 mm

1 7/16 in

1.4375 in

36.5125 mm

1 29/64 in

1.4531 in

36.9094 mm

1 15/32 in

1.4688 in

37.3063 mm

1 31/64 in

1.4844 in

37.7031 mm

1 1/2 in

1.5000 in

38.1000 mm