Enclosure shell concept for a residential electrical applianceBlind

in 3D Modeling Design held by JesseR
Contest Ended, Winner(s) have been selected.
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

1st Winner
#7 JesseR Enclosure II by Ridwan Sept
JesseR Enclosure II
more
Aug 3, 2019 5:12
#5 Jesser Enclosure by Ridwan Sept
Jesser Enclosure Files
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Aug 2, 2019 9:30
#3 Enclosure shell 2 by Mecanikad
Same shape according to the internal parts (that take a lot of place).
more
Aug 1, 2019 8:42
#10 ENCLOSURE by Will Snell
I'd be happy to work with you on any changes you'd like. Thanks!
more
Aug 3, 2019 21:33
#1 Enclosure shell 1 by Mecanikad
Hi please rate if you like. Flat parting line, no undercuts 4mm thickness. It can be adjusted on the inner parts.
Solidworks 100%.
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Jul 31, 2019 18:41
#14 Jesser Enclosure - Design 2 by Martin Arguello
I attended to your suggestions. Waiting for feedback.
Hope you like it!
more
Aug 7, 2019 17:45
#9 Enclosure by Jim81
Aug 3, 2019 19:37
#2 Jesser Enclosure - Design 1 by Martin Arguello
Meets all requirements. Hope you like it. Any suggestion let me know.
Working on others designs with different typologies.
more
Jul 31, 2019 19:36
#13 SHELL-ENCLOSURE by prashant kaushik
this is the screen shot of both the upper and lower part of shell enclosure.
- 4 mm thickness
- draft given
- easily moladable
- parting line in same plane
if you need i can design the mold this shell enclosure
more
Aug 5, 2019 7:53
#16 home appliance 01 by supra77
this my first design, internal components include.
add draft angle >2 degree
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Aug 7, 2019 23:49
#4 Enclosure shell concept for a residential electrical appliance V1 by Jean Marc Philippe
Made with a glossy front part, and a matte grey back part with a rubber like texture that integrates a connecting bracket for the wall mount attachement.
Front and back parts have an overall shell thickness of 4mm
Finished overall weight will have to be taken into consideration for both thickness and spacing of the integrated connecting bracket
Hope you like it
more
Aug 1, 2019 22:00
#8 Enclosure by Kumud Nand Thakur
Actually this is basic model design of that you mention in your description.
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Aug 3, 2019 13:14
#6 basic enclosure by Jeremy Benjamin
I'm attaching two versions- the files labeled "B" are an alternate idea, different than what's shown in the screen capture. The alternate "B" version violates your second requirement, about the two parts being separated by a single plane, but thought I'd throw it out there as an idea. Not sure if either of these is close to what you had in mind, but figured I'd take a stab at this.
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Aug 2, 2019 19:10
#11 Enclosure by Shashank
This has two parts. A bottom shell and a top cover. All of them can be injection moulded. We can discuss more on wall mounting options.
more
Aug 4, 2019 21:30
#35 Enclosure Shell Design 3 by ITS MADE EZY
This is a enclosure shell design modeled in solidworks as per the given and dimensions and constraints.
more
Aug 11, 2019 18:18
#28 industrial model by omar a. abdella
-im using light to emphasize where to insert connections(at the bottom of the appliance )
-also im using to indicate the power as shown in the middle part of the appliance
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Aug 10, 2019 15:34
#36 Enclosure Shell Design 4 by ITS MADE EZY
This is a enclosure shell design modeled in solidworks as per the given and dimensions and constraints.
more
Aug 11, 2019 18:21
#37 Enclosure Shell Design 4 by ITS MADE EZY
This is a enclosure shell design modeled in solidworks as per the given and dimensions and constraints.
more
Aug 11, 2019 18:24
#38 Enclosure Shell Design 4 by ITS MADE EZY
This is a enclosure shell design modeled in solidworks as per the given and dimensions and constraints.
more
Aug 11, 2019 18:25
#31 enclosure by Oggy
if u want i can make more changes as per your requirement.
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Aug 11, 2019 16:16
#26 modified electrical appliance by omar a. abdella
-a simply modified design of the given model .
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Aug 10, 2019 14:37
#34 Enclosure Design 2 by ITS MADE EZY
This is a enclosure shell design modeled in solidworks as per the given and dimensions and constraints.
more
Aug 11, 2019 18:10
#33 Enclosure Design 1 by ITS MADE EZY
This is a enclosure shell design modeled in solidworks as per the given dimensions and constraints.
more
Aug 11, 2019 18:06
#22 Enclosure shell by Fadi Sayegh
Hi Sir,
Please find the attachments files with internals components.
Kind regards.
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Aug 9, 2019 15:02
#23 Home-Appliance02(revision) by supra77
this my 1st design with revision of surface and single plane for mating face
more
Aug 9, 2019 16:36
#32 Enclosure shell concept by Mahbub
Thanks.
more
Aug 11, 2019 17:11

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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