{"id":66781,"date":"2019-10-24T01:59:12","date_gmt":"2019-10-24T08:59:12","guid":{"rendered":"https:\/\/www.ponoko.com\/blog\/?p=66781"},"modified":"2019-11-11T13:15:51","modified_gmt":"2019-11-11T21:15:51","slug":"mounting-and-protecting-custom-pcbs-with-laser-cut-faceplates-panels-and-enclosures","status":"publish","type":"post","link":"https:\/\/www.ponoko.com\/blog\/design-ideas\/mounting-and-protecting-custom-pcbs-with-laser-cut-faceplates-panels-and-enclosures\/","title":{"rendered":"Mounting And Protecting Custom PCBs With Laser Cut Faceplates, Panels And Enclosures"},"content":{"rendered":"\n
\"faceplates_and_enclosures_Ponoko\"<\/figure>\n\n\n\n

You\u2019ve put your heart and soul into building a custom electronics device with a supplier such as 4PCB<\/a>, Circuit Hub<\/a> or PCBWay<\/a>. While the soldering, connecting and working out any bugs is complete, you\u2019re not done\u2026yet.<\/p>\n\n\n\n

No, this piece of hardware perfection can\u2019t be left naked with its board and wires exposed for all the world to see. It must be protected from the elements so it performs as designed for years to come. You need a custom electronics enclosure<\/a>.<\/p>\n\n\n\n

Making The Perfect Parts For Your PCB Board <\/h2>\n\n\n\n

Unless you\u2019ve got some wicked wizarding skills, perfect faceplates or enclosures for your custom PCB boards typically can\u2019t be bought off the shelf and don\u2019t appear out of thin air with the wave of a wand. Rather, they have to be custom manufactured. Follow these four steps to make the perfect parts to complement your PCB board:<\/p>\n\n\n\n

Step 1: Identifying The Ideal Making Method<\/h3>\n\n\n\n

There are a number of ways you can make enclosures or panels for your electronics project. Which is right for you? Let\u2019s look at a few of the most popular options so you can decide.<\/p>\n\n\n\n

One of the first and most logical places to start is by looking at what\u2019s available off-the-shelf. In theory, this should be the least time-consuming and least expensive. Just grab it, mount the PCB and go.<\/p>\n\n\n\n

However, if you\u2019ve ever fallen down the rabbit hole of internet searches, you know that hours (or days) can pass without ever finding exactly what you want. The sizing is too big or too small. The aesthetics don\u2019t align with your vision. The materials aren\u2019t conducive to electronics. The price is ridiculous. Even if you find something that will work conceptually, it will most likely need some tweaking to actually work IRL.<\/p>\n\n\n\n

If off-the-shelf options leave you feeling like jumping off a cliff, take a step back from the edge. Making custom parts is the way to go.<\/p>\n\n\n\n

One option is designing a 3D model of an enclosure using a CAD system and then ordering it from an on-demand 3D printing manufacturer. Pros: Great results in terms of shape. Cons: Limited to prototyping materials used in 3D printing, mad skills required for computer modeling and the price may empty your wallet.There\u2019s got to be a better way, right? Say hello to laser cutting<\/a>.<\/p>\n\n\n\n

Lasers can cut and engrave flat parts from sheet materials such as plastic, metal and wood in any configuration you can imagine. The flexibility you have with laser cutting is unbeatable. Also, the materials selection<\/a> is HUGE, ensuring you have the right construction structurally and aesthetically\u2014for both prototypes and<\/em> production. Thus, you only have to use one manufacturing process to go from idea to prototype to product to market<\/a>.<\/p>\n\n\n\n

In addition to using 3D design tools, you can also work in 2D programs such as Illustrator and Inkscape; previous design experience isn\u2019t required. Pricing is affordable, and turn-around time is fast. Winner!<\/p>\n\n\n\n

Step 2: Determining What Kind Of Parts You Need <\/h3>\n\n\n\n

Before making the final determination if laser cutting is right for your electronics build, it\u2019s important to understand what can be made via laser cutting. The two most popular kinds of parts are faceplates\/panels and full enclosures\/boxes.<\/p>\n\n\n\n

Laser Cut Faceplates (Panels)<\/h4>\n\n\n\n

Do you have a partial enclosure, perhaps a speaker box<\/a> or DVD player<\/a> that you\u2019re repurposing? Laser cutting makes it easy to create a faceplate to exact dimensions you require.<\/p>\n\n\n\n

What about labeling? If you\u2019ve ever tried using stickers or printing, you may have found these rub off over time. Using the laser solves this problem, as text and graphics can be engraved for readability that stands the test of time. Check out the precision of the engraving on this faceplate:<\/p>\n\n\n\n

\"\"<\/figure>\n\n\n\n

You can also see there\u2019s great contrast between the faceplate itself and the engraved text. This is achieved by using two-color acrylics. When the laser engraves away the top color (red<\/a>, in this case), the underlying color (white) is revealed. It\u2019s a simple solution that is easy to design into your parts and eliminates the need for any hand-finishing for labeling\u2014and important consideration when making quantities to sell.<\/p>\n\n\n\n

Laser Cut Enclosures (Boxes) <\/h4>\n\n\n\n

If your electronics project requires an entire custom enclosure, there are several different ways to construct boxes using laser cutting.<\/p>\n\n\n\n

Panel enclosures, as the name suggests, use one piece of laser cut material for each wall of the enclosure. This acrylic box is made from 3mm matte black acrylic<\/a> (matte keeps fingerprints at bay) as is paired with a white-on-black acrylic<\/a> faceplate.<\/p>\n\n\n\n

\"\"<\/figure>\n\n\n\n

Notice that the panels are held together using tabs. When constructing panel boxes with tabs (or finger joints), you must incorporate material thickness in the design in order for all pieces to fit together properly. MakerCase<\/a> is a great resource for help when designing using this method.<\/p>\n\n\n\n

Panel enclosures can also be held together with clips\u2014no glue or screws needed\u2014such as this Stacking Pi Case<\/a>. Congo Jo designed this case so multiple Raspberry Pi units could be stacked on top of one another in a tower format. White-on-black acrylic was used here to illustrate not only how graphics look when engraved but also the contrast of the edge cuts, which gives the box even more dimension.<\/p>\n\n\n\n

\"3mm<\/figure>\n\n\n\n

Not to be confused with the \u201cstackable case\u201d above, this Rainbow Pi<\/a> by Adafruit stacks layers of laser cut acrylic upon one another to build a simple enclosure that\u2019s great for beginners. While you don\u2019t have to use every color in the rainbow, it sure looks sweet when you do.<\/p>\n\n\n\n

\"Electronics<\/figure>\n\n\n\n

When building a layered case, some kind of hardware or fixtures (the little plastic screws) must be used to hold the layers securely together. It\u2019s also interesting to note how this case takes advantage of layering to create internal walls to isolate and mount components.<\/p>\n\n\n\n

While these aren\u2019t the only ways to make box enclosures, these examples should give you an idea if laser cutting is right for you. If so, keep reading.<\/p>\n\n\n\n

Laser Cut Fixtures And Panels<\/h4>\n\n\n\n

Wires and PCB boards often just need something solid to mount onto, and laser cut panels are perfect for this application. This example by Wes Westhaver<\/a>, a software developer who leans toward software\/hardware integration projects, demonstrates a rear mounting panel made from laser cut clear acrylic<\/a>.<\/p>\n\n\n\n

\"Comvette<\/figure>\n\n\n\n

Step 3: Designing Your Parts For Manufacture (DFM) <\/h3>\n\n\n\n

Now that you\u2019ve decided laser cutting is right for your electronics project, it\u2019s time to have some fun and start designing. Laser cutters work on vector artwork, a mathematical point and line system that allows text and graphics to easily be scaled without losing resolution or clarity. Thus, files must be prepared using vector-based design software.<\/p>\n\n\n\n

You can build laser cutting files in two main ways. The first is to manually measure and \u201cdraw\u201d flat shapes or lines in a 2D modeling program, such as Adobe Illustrator or Inkscape, and export an SVG file.<\/p>\n\n\n\n

The second is to export your PCB design file in DXF format from your engineering software, then import it into CAD software (AutoCAD, Fusion360, Rhinoceros 3D, TinkerCAD, etc.) where you\u2019d build a 3D model of your full enclosure. From there, export a DXF file that contains only the cutting lines needed for your flat laser cut parts.<\/p>\n\n\n\n

The file you output for laser cutting should be a 2D vector drawing with a different color applied to parts you want cut vs engraved. For example, here is a screenshot of the design file used for the faceplate examples above.<\/p>\n\n\n\n

\"\"<\/figure><\/div>\n\n\n\n

Either way you go, make sure to incorporate these five design considerations into your parts.<\/p>\n\n\n\n

Use <\/h4>\n\n\n\n

How your device will be used will determine how the enclosure is constructed. Will it sit on a shelf or will it need to withstand transport? Think about use to determine how secure the enclosure must be to protect components from the elements and movement.<\/p>\n\n\n\n

Dimensions <\/h4>\n\n\n\n

From there, determine the dimensions required. While faceplates are pretty straightforward, boxes can be a bit more complex. The interior size must be able to contain all components, plus you want to have at least an extra 1\/16\u201d clearance space. Additionally, if you have outward facing components (LEDs, buttons, switches, potentiometer, 7 Segment Displays or even small LCD screens), leave enough room to make those crucial electrical connections.<\/p>\n\n\n\n

Mounting<\/h4>\n\n\n\n

While it\u2019s possible to secure a PCB in an enclosure with hot glue or a dab of epoxy, using adhesive material is not a permanent solution. A better strategy is to use screws, standoffs, threaded inserts, locking nuts, o-rings or other special washers to keep components in place, insulate exposed connections, and protect your board from external vibration or movement. Knowing how components will be mounted will help you include the appropriate cuts in your design from the very start.<\/p>\n\n\n\n

Accessibility <\/h4>\n\n\n\n

Once your electronic device is housed in an enclosure, what kind of access to components is required? It\u2019s reasonable to be able to plug into a power supply, recharge a battery or allow access to a replaceable battery. Consider where these (and other) components are placed on the board to allow for easy access from outside the enclosure.<\/p>\n\n\n\n

Finish <\/h4>\n\n\n\n

The professional finish of laser cutting can\u2019t be beat. Unlike the textured look of 3D printing, laser cutting is silky smooth, features clean cut lines and offers engraving options to enhance the users interaction with your device. It\u2019s good for both prototypes and final products.<\/p>\n\n\n\n

Acrylic is a great choice, as there are tons of colors and finishes to offer personality and refinement for your build. For those who want a metal look, there are brushed silver<\/a> (shown) and brushed gold<\/a> acrylics that simulate metal but at a much nicer price point\u2014plus you don\u2019t have to worry about any pesky conductivity that might mess with circuits.<\/p>\n\n\n\n

\"\"<\/figure>\n\n\n\n

In addition to the two-color acrylics above, there\u2019s a rainbow of solid color acrylics, translucent acrylics and clear acrylic. There\u2019s even glitter acrylic<\/a> for those who want to add a touch of whimsy and a bit of bling.<\/p>\n\n\n\n

\"\"<\/figure>\n\n\n\n

Step 4: Laser Cutting Parts<\/h3>\n\n\n\n

Once the design files are prepared, it\u2019s time to start cutting! If you don\u2019t have access to a laser cutter at a local makerspace or university, Ponoko<\/a> can help. We are an online cloud-to-robot laser cutting service that can make the custom parts you need\u2014from the simple to the sublime.<\/p>\n\n\n\n

If you are looking for or are already familiar with online PCB manufacturers such as Bay Area Circuits<\/a>, JLCPCB<\/a>, Macro Fab<\/a>, OSH Park<\/a>, Screaming Circuits<\/a>, Seed<\/a> or Tempo<\/a>, you\u2019ll find Ponoko is similar in that we also use an automated, online process to help engineers and pro makers order their hardware parts. Once you build the smart parts of your device, you can laser cut the finished shell or skin at Ponoko to complete the build. Together, online PCB manufacturers and Ponoko enable you to take a device all the way from concept to professional finished product, to thrive in the real world.<\/p>\n","protected":false},"excerpt":{"rendered":"

You\u2019ve put your heart and soul into building a custom electronics device with a supplier such as 4PCB, Circuit Hub or PCBWay. While the soldering, connecting and working out any bugs is complete, you\u2019re not done\u2026yet.<\/p>\n

No, this piece of hardware perfection can\u2019t be left naked with its board and wires exposed for all the world to see. It must be protected from the elements so it performs as designed for years to come.<\/p>\n","protected":false},"author":58,"featured_media":0,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[22,5796],"tags":[],"class_list":["post-66781","post","type-post","status-publish","format-standard","hentry","category-how-to-make","category-design-ideas"],"yoast_head":"\nMounting And Protecting Custom PCBs With Laser Cut Faceplates, Panels And Enclosures<\/title>\n<meta name=\"description\" content=\"Together, online PCB manufacturers & Ponoko enable you to take a device from concept to professional finished product, to thrive in the real world.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" 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