Enclosure shell concept for a residential electrical applianceBlind

in 3D Modeling Design held by JesseR
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Description:
I'm developing an electronic appliance for residential use, and am looking for help with the enclosure design. Specifically, I'm looking for help with the exterior design of the enclosure (i.e. just the shell); I can handle the detailed design.

The enclosure will be two piece injection molded, with a front and back. I've included cad files (solidworks and step) that captures the dimensions of the internal components and the minimum spacing between the components, along with the target distance of the components from the wall it'll be mounted on. The dimensions in the cad file denote the minimum size including clearance, but the enclosure can be larger if necessary (e.g. wider, taller, etc).

I've attached an example enclosure that is similar to the profile that I'm looking for. You'll notice that it has a softly contoured face, while the back half lofts down to a boss feature to allow for connection to a wall mounting bracket. I plan to use the same approach for mounting. The idea is that you can use the example for inspiration, although it is not intended to be a 1:1 copy.

Specific Requirements:
1. The design must be symmetrical across it's vertical mid-plane (i.e. left and right are the same).
2. The design must have a single plane as a parting line between the front and back parts (i.e. the two halves must have flat faces where they meet).
3. Each part must be moldable, with ideally a minimum draft angle of at least 1 degree. No undercuts or sharp edges which can't be radiused later are allowed.
4. The cylinders shown in the internal components cad file must be completely contained within the back piece of the enclosure.
5. The wall thickness of the enclosure should be 4mm.

The deliverable should be cad files of the two enclosure shell parts. The design must be thickened to 4mm (providing surfaces only won't cut it). Ideally the cad would be native solidworks, but step files are ok if you prefer a different program.

Please let me know if you have any questions or if any more information is needed. Look forward to seeing what you come up with!
Wants:
Designs will be evaluated on aesthetics, along with meeting the specific requirements listed in the description above.

Entries

= Buyer's Rating
1st Winner
#7 JesseR Enclosure II by Ridwan Sept
Aug 3, 2019 5:12
#5 Jesser Enclosure by Ridwan Sept
Aug 2, 2019 9:30
#9 Enclosure by Jim81
Aug 3, 2019 19:37
#37 Enclosure Shell Design 4 by ITS MADE EZY
Aug 11, 2019 18:24
#36 Enclosure Shell Design 4 by ITS MADE EZY
Aug 11, 2019 18:21
#38 Enclosure Shell Design 4 by ITS MADE EZY
Aug 11, 2019 18:25
#35 Enclosure Shell Design 3 by ITS MADE EZY
Aug 11, 2019 18:18
#34 Enclosure Design 2 by ITS MADE EZY
Aug 11, 2019 18:10
#33 Enclosure Design 1 by ITS MADE EZY
Aug 11, 2019 18:06
#32 Enclosure shell concept by Mahbub
Aug 11, 2019 17:11
#31 enclosure by Oggy
Aug 11, 2019 16:16
#28 industrial model by omar a. abdella
Aug 10, 2019 15:34
#26 modified electrical appliance by omar a. abdella
Aug 10, 2019 14:37
#22 Enclosure shell by Fadi Sayegh
Aug 9, 2019 15:02

Discussion

JesseR

Buyer

Mon, 05 Aug 2019 19:17:36 +0000
Hi Kandar,

I don't know what the interface looks like for makers, but there should be an option to submit a design for the contest. Perhaps reading through the help section?
Sat, 03 Aug 2019 08:28:44 +0000
Hi,
Sorry, I'm a newcomer here.
Do I only offer buyers first?
or directly make a design according to the description and put in an attachment?
Thu, 01 Aug 2019 14:25:31 +0000
Look up UL 2594,EVSE standards. I can't help, conflict of interest.

Martin Arguello

Designer

Wed, 31 Jul 2019 14:55:14 +0000
Understood

JesseR

Buyer

Wed, 31 Jul 2019 14:32:44 +0000
Yep it's going to have a few light pipes, but I'm going to handle that when I do the detailed design. I'm just looking for aesthetically pleasing shell concepts (which I'm personally terrible at).

Martin Arguello

Designer

Wed, 31 Jul 2019 13:48:56 +0000
Ok, 4 mm thickness then!

Martin Arguello

Designer

Wed, 31 Jul 2019 13:47:05 +0000
Hello, another question. Is it any of the components a led? The example you attached has a power light. Do you want something like this in your appliance?

JesseR

Buyer

Wed, 31 Jul 2019 13:28:15 +0000
Hi Martin,

Good question. The 4mm is due to external fittings which require a particular wall thickness. There'll also be face seals in certain areas which will need at least 3mm thickness. Most of the off-the-shelf ABS/PC NEMA enclosures are also in the 3-4mm thickness range for the similar enclosure size. So I'm erring on it being more robust than less.

Let me know if you have any other questions!

Martin Arguello

Designer

Wed, 31 Jul 2019 13:14:05 +0000
Hello Jesser, the 4 mm thickness has a specific purpose? Is it not too thick just for a injection molding enclosure? I mean, it could be thinner (i. e. 1,5mm) with some reinforcement ribs inside. Less weigth, shorter cycle injection time, less cost per unit.
Thanks

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