Power Supply Enclosure

Project Overview

We were engaged by a green‑energy company to develop a weatherproof power‑supply enclosure tailored to low‑volume production. The enclosure needed to protect sensitive electronics outdoors while remaining simple to assemble and primed for future injection‑moulding.

The Challenge

Our client faced high labour costs and small production runs that didn’t justify immediate injection‑mould tooling. The enclosure had to achieve full IP67 weatherproofing, be quick and intuitive to assemble on a lean production line, and incorporate design features compatible with eventual injection moulding.

Our Solution

We opted for 3D‑printed parts for the initial batch, designing snap‑fit joints, alignment guides and integrated gasket channels to speed assembly and ensure a reliable seal. By studying the client’s existing workflow, we simplified each step, cutting out unnecessary handling and tool changes. At the same time, we built in draft angles, part consolidation and material choices to make the design injection‑mould ready when volumes grow.

Results

The first run of 3D‑printed enclosures passed IP67 weatherproof tests and slashed assembly time by 50 %, significantly reducing labour costs. With the design already optimised for injection moulding, the client can scale up production seamlessly. They are delighted with the faster turnaround and cost savings and ready for the next phase of their product launch.

Project Details

Client

Confidential Client (under NDA)

Location

Auckland, New Zealand

Year

2025

Services Provided

Concept Development, Industrial Design, Engineering Design, Prototype, Production, Supplier Management

Technologies Used

Hand sketches, CAD, 3D printing, prototype assembly, prototype testing, electromechanical assembly