enclosure holes and I/O - Page 1
Forum section: electronics / projects

author: guimtl
author_rank: Contributor
timestamp: February 20, 2017, 03:05:23 am
content: Hello,I'm looking around for a good enclosure for a project that contains a few boards and wires. I think Hammond manufacturing is the best bet for a aluminium solid case for this uses.Now id like the best way to create the I/O and mount all components inside. I plan to make about 100 to 500 boxes per year(that's my target, loll). My first two attempt I've used many tools. Press Drill, Dremel, jig saw, lime and the end result is not exactly what I can call a perfect job.Hammond offers milling and drilling options but I didn't reached their sales yet. Curious what is people ideas or suggestions.I would have to open access to about 5-6 holes for 2x usb (how to drill out a rectangle) , power DC in, power switch, audio, a few led holders, maybe lan.So I thought I could either make a small I/o plate at local metal shop and screw it from the inside. Or cutouts all port individually from the enclosure side wall.I've tough It could be done using a small Cnc maybe but not sure if I can afford the investment and witch kind i would need... I guess only a very basic model could be working since my enclosure is very small about max 200mm on each sides..Any ideas or suggestions?

author: edpalmer42
author_rank: Super Contributor
timestamp: February 20, 2017, 04:36:47 am
content: Quote from: evb149 on February 20, 2017, 04:13:13 amHere's an example of a PCB used as a front panel.http://www.ebay.com/itm/172538628779Ed

author: qwaarjet
author_rank: Regular Contributor
timestamp: February 20, 2017, 06:17:08 am
content: I have had a lot of luck withhttp://www.protocase.com/to build complex enclosures typically 19" rack style but have done some other novel builds as well. I also make heavy use of there engineering service, which for what they charge I couldn't do the detailed engineering my self for that price.

author: edpalmer42
author_rank: Super Contributor
timestamp: February 20, 2017, 06:45:39 am
content: There are also places likehttps://www.frontpanelexpress.com/that can do a front panel in a variety of materials with engraved text and graphics to use with an extruded aluminum box. Looks amazing!Ed

author: coppice
author_rank: Super Contributor
timestamp: February 20, 2017, 07:59:31 am
content: Some people get good results with PCB front panels, and some don't. The wear tolerance of PCB silk screening varies a lot. In their normal application they don't need to tolerate much wear, so it's not a major factor in a PCB maker's decisions.

author: Someone
author_rank: Super Contributor
timestamp: February 20, 2017, 09:44:33 pm
content: Quote from: evb149 on February 20, 2017, 04:13:13 amIf you go shopping for a metal manufacturer you can get steel or aluminium, painted and screen printed for the same price per unit area as a PCB. PCB panels are only cost effective if you're embedding some circuitry in/on it, or you're making very few and use the PCB pool services with low (or no) NRE charges.

author: Farley
author_rank: Regular Contributor
timestamp: February 20, 2017, 09:59:21 pm
content: Contact local machine shops with CNC capability. At the 100 to 500 qty it is likely cost effective to have it done professionally. Don't be afraid to arrange for a personal visit, show them what you want and look at their capabilities and other parts they've done.

author: Dubbie
author_rank: Unknown
timestamp: February 20, 2017, 10:22:57 pm
content: Another option could be finding a set of punches that do what you need and using a small press. You could probably knock out 100 in an hour easily.It might not be a good option if you don't have access to the right tools though

author: guimtl
author_rank: Contributor
timestamp: February 21, 2017, 04:51:22 am
content: Thanks to all repliesreally appreciatedI'll get pictures of the final results as well as my very first sample if I win the deal..

author: Paul Moir
author_rank: Frequent Contributor
timestamp: February 21, 2017, 05:28:09 am
content: The sample cases I've seen from Hammond make me think they're getting them laser cut, so don't forget to check with your local laser and waterjet guys. They tend to cost out more from setup than per feature like a CNC mill can do, and can do square corners cheap.

author: james_s
author_rank: Super Contributor
timestamp: February 21, 2017, 05:36:19 am
content: I would either find a local CNC machine shop, or make a drill template out of steel that you can use to drill them yourself. Without a template it's going to be very labor intensive and tricky to get it perfect.

author: rstofer
author_rank: Super Contributor
timestamp: February 21, 2017, 05:35:36 pm
content: I built up a CNC Mill from a Grizzly G0704 so I could build the front panel for my analog computer. Basically, I needed about 100 perfectly spaced holes. There are projects on the Internet that detail the conversion.

author: IanJ
author_rank: Unknown
timestamp: February 22, 2017, 11:51:37 am
content: Quote from: guimtl on February 20, 2017, 03:05:23 amHi,I use Hammond's custom milling/drilling service here in the UK........their process is pretty good. Fees aside, just pick an enclosure, make a sketch and send to them. They'll produce a drawing which you mark up/approve, then they send you 1off milled & drilled example. Any changes then mark up the drawing and send back for final approval to production.They'll drill or mill holes on any face etc. I have just approved milled cutouts on the sloping sides of an ABS enclosure.Quality & accuracy of their milling is spot on.Ian.

author: bson
author_rank: Unknown
timestamp: February 22, 2017, 11:43:41 pm
content: Quote from: edpalmer42 on February 20, 2017, 06:45:39 amI've used FPE and they do a good job. They're limited in what they can do, and they're expensive. A non-trivial panel can easily cost $100; not a big deal for a prototype, but definitely someplace you can save money if you need even 100 of them, even more so if you need two (front & back) for each enclosure. Be also aware that if you buy a black anodized panel they will mill your panel out of an anodized block, exposing shiny metal, rather than anodizing it after the cutouts.