IoT Sensor with 3D printing enclosure

Introduction

In electronics design, the enclosure plays a crucial role in protecting and providing functionality to internal components, directly influencing the usability, aesthetics and durability of the final product. However, many designers face significant challenges when creating professional electronic enclosures, especially when relying on traditional manufacturing methods.

Design complexity, limited materials and constraints imposed by conventional production processes can result in enclosures that do not fully meet the design needs, compromising both the physical integrity and operational efficiency of electronic devices.

Lack of access to advanced manufacturing technologies, such as industrial 3D printing, can lead to design flaws, development delays and high production costs. Designers who underestimate the importance of a well-designed enclosure risk launching less competitive products on the market, negatively impacting the user experience and device longevity.

In this article we will address the development of an electronic project for an IoT sensor for monitoring temperature and humidity, as shown in the figure below. From this monitoring, the data will be sent to a web platform.

In this way, it is possible monitor various parameters, store this data, perform statistical analyses and carry out scientific studies to monitor various environments.

If you want to manufacture this project, click here.

Equipment like this can now be developed at a very affordable price.

Our main approach is to present the great impacts that printing can bring to the development process of electronic electronic, allowing the creation of innovative and personalized designs that meet the specificities of each project.

Development of electronic enclosures for electronic projects

Every day, countless electronic projects are developed and several electronic boards are created. What do these electronic boards that appear on the market have in common? Do you know?

They require storage mechanisms, that is, every electronic project requires an enclosure to install the printed circuit board.

Take, for example, this printed circuit board that is designed to monitor the temperature, humidity and pressure of a location.

Reflect on the following points below.

• Do you know why it is important to develop an electronic enclosure?
• How do electronic enclosure affect the usability and perception of product quality?
• Do you know how we can develop any electronic enclosure at low cost from 1 unit, spending little and using industrial quality manufacturing technology?

The development of electronic enclosure is of fundamental importance to ensure, firstly, the protection of the electronic circuit, usability and increased perception of quality of an electronic product.

In the past, developing electronic housings for equipment was a very expensive process and required specialized labor, since all projects were developed using thermoplastic injection molding technology. This prevented many designers from testing a product and launching it on the market, since the process was expensive and required the production of high-quality samples.

With the advancement of 3D printing technology, there has been a huge leap forward in the construction of prototypes.

Industrial 3D printing is a major advancement in manufacturing technology and has positively impacted project manufacturing due to its surface finish and final similarity to mold-injected parts.

What are the requirements needed to develop an electronic enclosure for a product? Next, we will discuss the complete structure of the design requirements and construction process of the electronic prototype enclosure.

Requirements of the development process of an electronic enclosure for IoT Sensor

All of this is thanks to advances in technological development that have allowed lower costs in electronics and additive manufacturing technology with 3D printing.

Do you know what to take into consideration during the development process of an electronic enclosure? What requirements must we follow to achieve the desired result?

Before answering these and other questions, take a look at the electronic structure of our electronic enclosure.

Designing an electronics enclosure like this involves considering several factors to ensure that it meets the needs of the project, both in terms of functionality and aesthetics. Here are the main factors to consider:

Internal Dimensions and Spacing: Make sure the enclosure has enough space to accommodate all electronic components such as printed circuit boards, connectors, batteries, etc.

Consider the layout and arrangement of internal components to facilitate assembly and maintenance. Below we have the internal structure of the electronic housing.

The electronic boards are accommodated to ensure a compact design and have enough space to attach a LiPo battery to power the electronic circuit.

The project's electronic circuit consists of 2 electronic boards: the board responsible for charging the LiPo battery and the IoT sensor board. The connection between them is made through a pair of connector wires to power the IoT sensor circuit.

Electronic Enclosure Material: Choose the appropriate material, taking into account durability, impact resistance, thermal properties and compatibility with the environment in which it will be used.

Common materials include plastics such as ABS and polycarbonate, as well as composites and resins for specific applications.

Thermal Management: Plan for heat dissipation, especially if the design involves components that generate significant heat, such as processors or power supplies.

Consider including ventilation openings, heat sinks, or materials with high thermal conductivity.

Sealing and Environmental Resistance: Evaluate the need for protection against dust, moisture, and liquids, especially if the device will be used in outdoor or industrial environments.

Consider the IP (Ingress Protection) rating required for your project and design the enclosure with appropriate seals. This equipment does not require a high level of protection, as it will be built into indoor environments.

Electromagnetic Interference (EMI) Protection: If the design involves sensitive circuits or circuits that operate at high frequencies, it is important to protect the enclosure from electromagnetic interference.

Consider using materials with EMI shielding properties or internal coatings that block such interference.

Ergonomics and Usability: The enclosure should be comfortable and easy for end users to handle. Consider ergonomic design and the positioning of buttons, connectors, and displays.

Ensure that the design allows easy access to critical components for maintenance or replacement.

Aesthetics and Design: The appearance of the electronic enclosure can influence the perception of the final product. Consider industrial design, colors and finishes that reflect the brand and product identity.

Balance aesthetics with functionality to create an attractive and practical electronic enclosure.

Ease of Assembly: Design the enclosure to facilitate assembly and disassembly of internal components, considering the need for screws, clips or fittings that can be used efficiently.

Consider using fasteners that allow for quick assembly and reduce production time. In this project we will use glue specifically for use in the electronics field to close the electronic housing cover.

Cost and Economic Viability: The design must be economically viable, considering the cost of materials, manufacturing process and assembly time.

Evaluate the cost-benefit ratio of each choice to ensure that the project meets the budget without compromising quality.

Manufacturing Method: Consider the limitations and capabilities of the chosen manufacturing method, such as 3D printing, injection molding, machining, and others.

Ensure that the electronic enclosure design is compatible with the manufacturing process to avoid complications during production.

After all, what is the best method to develop your first electronic enclosure? The best method is industrial 3D printing and this will directly impact the manufacturing cost of the first version of your product.

Industrial 3D printing and electronic prototyping

A few years ago, developing a sensor like this was very expensive, as it was necessary to develop thermoplastic injection molding tools to create the product's electronic casing.

The costs of designing the project were high and prevented testing and validation. However, industrial 3D printing has changed the market reality and, today, allows any 3D printing solution to be developed and tested at a very low cost.

To facilitate design validation and reduce prototype manufacturing costs the industrial 3D printing is our greatest ally in the development of electronic enclosure.

Unlike traditional processes, such as injection molds, industrial 3D printing offers a very cheap and fast manufacturing process and, most importantly, high-quality surface finishes for the part through several post-processing steps.

This electronic housing, with a very compact design, has dimensions of 60mm in diameter and 20mm in height. Do you know how much it costs to manufacture just one unit?

Today, you can develop any electronic enclosure and create your own product by spending few money on the manufacturing process of an electronic enclosure. This electronics enclosure design cost just $2.29 to manufacture using industrial 3D printing.

In addition to manufacturing your projects, it is possible to carry out a professional painting process on your piece to increase the level of finish and manufacturing quality. See below.

Know the initial cost of manufacturing any part. Everything starts from $0.3 and, from today, JLC3DP can be your ally in manufacturing any electronic prototype with low manufacturing cost and manufacturing quality.

In a market where innovation and speed of development are crucial, industrial 3D printing stands out as a powerful tool for creating electronic enclosures.

Final considerations

With its design flexibility, rapid prototyping capabilities, and customization capabilities, 3D printing allows engineers and designers to efficiently and accurately transform ideas into real products.

In addition, the choice of materials and the possibility of mass production make this technology an affordable and adaptable solution to the needs of any project.

At JLC3DP, we understand the importance of every detail in the development of electronic enclosures and other products. Our customer support team is always ready to help at every step of the process, from receiving and analyzing the file, to providing guidance on choosing the most suitable materials, and finalizing production.

Whether you are working on an innovative prototype or a mass production, our specialized team will ensure that your ideas become reality with the highest quality.