Design Guide

76 Walker Road, Shirley, Massachusetts 01464 USA T 978.425.2311 F 978.425.2305 www.thermofab.com

Custom Plastic Enclosures. Revolutionary Process.

Design Guide
The intent of this guide is to assist the engineering team in their work to design custom plastic enclosures. This guide will also include considerations for product design when designing custom plastic enclosures for ThermoFab.

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Table of Contents
1.0 Design Basics 1.1 Rendering Examples 1.2 Preferred File Types 1.3 Materials List 1.4 Base Material Field of Color 2.0 Custom Design Considerations 2.1 Overall Design 2.1.1 Radii 2.2 Lap Joint Design 2.3 Vent Details 2.4 Internal Ribs Design Preferences 2.5 Perforation Options 2.6 Internal Pressure Vents 2.7 Lightpipes 3.0 Tooling Design 3.1 Tooling Materials 3.2 Tooled in Logos 3.3 Undercuts and Action Undercut detail, .150 wall 3.4 Label Recess Design Criteria 3.5 Tooling Finish : Clear & Tinted Parts 4.0 Hardware Considerations 4.1 Ball Stud Specs 4.2 Insert Specifications Short Inserts Regular Inserts Flanged Inserts 4.3 Boss Design for Flanged Inserts 4.4 Captive Screws 5.0 Finish Considerations 5.1 Paint Finish 5.2 Min/Max Chips 5.3 Paint Lines for Two-Tone Parts 5.4 Logo Artwork Design 6.0 EMI Shielding 6.1 Nickel Coating 6.2 Gasketing 7.0 Quality Assurance 7.1 CMM 7.2 Exterior Finish Control
See 5.2 Min/Max Chips

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1.0 Design Basics

Design Giving your product every chance at success is, no doubt, your top priority. We'll get your product to market faster and with higher quality (because of the design and details) than other manufacturers. And we don't have to tell you what that means: the sooner your product is on the market, the more units you can sell. At ThermoFab, we feel the same way, which is why we're not only equipped to work with designers you bring to the table, but we're also equipped with design experts and engineers in-house who can turn your product dreams into reality. Details As the old saying goes, the devil is in the details, and the same holds true for plastic enclosures that house sensitive medical, computer, electrical, and other industrial products. We've developed a proprietary process that offers close tolerances, tight specifications, and sharp detail. Speed As you know, the time-to-market (TTM) interval (the time needed to develop a new product) is critical to success. But reducing TTM won't be enough, if it means the product's integrity is affected due to shortcuts or untested processes.

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1.0 Design Basics - Continued

Work with a manufacturer that has in house designers or an experienced designer. But don't overdesign. Remember, plastic is flexible. It moves. Keep in mind "tolerance stack-up": how many components are stacking up and mating together? Work with an industrial designer or engineer who has designed for plasticnot all designers have. Keep the end phase in sight, even when you're in the prototype phase. We believe the prototype should provide a solid idea of what the final manufactured product will look like. To accomplish this, you need to think about your brand, colors, the location of labels, etc. now. Use production-grade plastic. Production-grade plastics will provide a better idea of how the final product will look and work. It's definitely worth the investment to have a working prototype in the end, the key word being "working." At the same time, be mindful of where you can save dollars. For example, you might be able to use CNC machining and soft tooling to create the initial production pieces.

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1.1 Rendering Examples

Images 1-3

Initial Design Rendering Concepts are created for Phase I of the design process. Usually 2-3 Concept Views are Created First (Images 1-3). The Initial Renderings are reviewed and details are chosen that are preferred. The process narrows down the design elements so that a final look is created (Image 4).

Image 4
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1.2 Preferred File Types

Solid Model File Formats: SolidWorks Native Files IGES Parasolid (.XT Files) ProEngineer Native Files

2D Drawing File Formats: SolidWorks .DWG Files DXF DWG PDF

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1.3 Materials List

Materials: Flame-retardant ABS Starex KYDEX sheet Acrylic/PVC ABS PVC GE Lexan Bayer Polycarbonate Acrylics High impact polystyrene (HIPS) Typical Products: Custom Enclosure Equipment Housings Shrouds Covers Bases Bezels

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1.4 Base Material Field of Color

Image 1 is a photo of raw material samples. Base material color is closely matched to final paint color. Image 2 shows silver finish paint on base grey material.
Image 1 Raw Material Samples

Below are examples of base colors:

Image 2 Finish Painted Part
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Black Grey Natural White

2.0 Custom Design Considerations

You may find yourself saying: Ive never designed for ThermoFab before where do I start? There are many details that must be considered during the design and engineering phases. The details in this section will assist you as you put the finishing touches on your 3D Model Files.

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2.1 Overall Design

Helping You Go From Ideas To Implementation With over 30 years experience, ThermoFab knows whats required to take your design files and transform them into a product that your clients want to buy. In-house design, tooling, painting, EMI shielding, and other custom processes provide a level of detail and quality that other companies cant achieve. A dedicated team of experts works closely with product designers to review your designs and provide the tooling you need to ensure manufacturability. Our experienced in-house manufacturing staff then takes the lead to produce your custom plastic enclosures exactly to your specifications. From design review to tooling to manufacturing to painting and shielding and even assembly, we have the quality systems in place to ensure your finished product delivers.
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2.1.1 Radii
Maintain Constant wall thickness if possible .125 wall recommended Exterior R .020 MIN

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2.2 Lap Joint Design

Image 1: Shows Preferable Lap Joint Design o Minimum Wall is .120 o Minimum Draft @ Joint Interface= 3 Degrees

Image 1 Preferred Lap Joint Design Minimum Wall Thickness is .120 Preferred 3 deg. Minimum Draft at Joint Interface.

Image 2: o Not recommended Undercut design

Image 2 Design Not Recommended: Undercut Around Part Traps Inner Core.

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2.3 Vent Details

Vent details not only handle needed airflow requirements, but also create design style as well. Simple to intricate design lines can be created with a venting detail. Images to the left show rectangular, oval, and even cylindrical vent detail.

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2.4 Internal Ribs

Image 1: Showing the underside ribbing structure added to a product design. The base of the rib should be no more than 2/3 of the nominal wall in thickness. The top of the rib should be no less than .035 thick. Image 2: The green highlighted walls show recommended minimum degree of draft per side for tall ribs. Preferable 1 degree draft per side.

Image 1

Image 2

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2.5 Perforation Options

Image 1 Image 2
Image I

Image 1 & Image 2:

Aluminum Hex perforation backing used in bezel design

Image 3

Image 4

Image 3 & Image 4:

1/8 PVC Round perforation used in bezel design

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2.6 Internal Pressure Vents

At ThermoFab, one of the keys to our proprietary process is that we're creating a core that creates a part that has significant detail molded in. Our proprietary process allows for an extra 40 to 50 percent more detail than traditional thermoforming. In fact, the details are so precise, our thermoformed plastic enclosures look injection molded. Here's an example that illustrates our strong commitment to the tooling process. Image 1: The interior view of the part below shows the pressure vent indentations that make the detail possible in the process.

Image 1
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2.7 Lightpipes
Here are some custom lightpipe designs. Custom lightpipes are formed and created with specific diffusing properties as the project requires. Back-lighting the lightpipe creates additional visual highlight.

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3.0 Tooling Design

Temperature controlled aluminum tooling Maintains maximum control over the entire tooling process Successful tooling requires:
A skilled craftsman who considers the plastic, shrink, and aluminum tooling necessary to create the desired parts from your 3D files The ability to make necessary changes and refinements quickly so your project stays on deadline and your product performs as intended

Features:
Blind venting Louvers Undercuts Molded logos

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3.1 Tooling Materials

ALUMINUM STEEL HIGH TEMP REN (Soft Tooling for Prototype Only)

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3.2 Tooled in Logos

Logos are tooled in precisely. The details are amazing and are often highlighted with additional finishing options, such as paint, texture, appliqus, or lightpipes.

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3.3 Undercuts and Action

Image 1

Image 1 shows the model file, which was a unique part. The color was tinted and two tone. The handle design and pivot point were handled with undercut action designed into the tooling. Image 2 shows the integrated door with the undercut handle at the top in the completed assembly.

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Image 2

3.4 Label Recess Design Criteria

Image 1

Labels work best in a thermoformed piece when they are recessed into the design itself. Recessing provides a finished look that cannot be achieved by affixing the label in any other way. Recessing prevents the label from getting torn off when shipped or during everyday use. Image 1 shows the finished design and the placement of the label at the top. Image 2 shows the actual part.

Image 2
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3.4 Label Recess Design Criteria - Continued

Images 3 and 4 show the design details associated with the label recess
Image 3

Recess Should be .005-.010 Deeper than Label Thickness

Image 4

Recommend .005.010 Larger all around

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3.5 Tooling Finish - Clear and Tinted Parts

Recommend A-2 Finish for Clear and Tinted Parts Tooling Finish Polish Guide Examples:
Polish
A1 A2 A3 B1 B2 B3 C1 C3 D1 D2 D3

Guide
GRADE #3 DIAMOND BUFF GRADE #6 DIAMOND BUFF GRADE #15 DIAMOND BUFF 600 GRIT PAPER 400 GRIP PAPER 320 GRIP PAPER 600 STONE C - 2 400 STONE 320 STONE DRY BLAST GLASS BEAD #11 DRY BLAST #240 OXIDE DRY BLAST #24 OXIDE

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4.0 Hardware Considerations

Design attachment detail question examples are: How will your products attach to the inner framework chassis? How will the structure be laid out in the design detail? How will your bezel front attach to the metal frame? Does the product have to hinge open? Lock? Have specific access requirements?

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4.1 Ball Stud Specs

Image 1 Fastening Clip Top View

Image 1 & 2

Image 2- Fastening Clip Side View

Image 3 Ball Lock Stud Detail

Image 3

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4.2 Insert Specifications

Insert specifications and boss design are critical elements to designing your plastic enclosure. How will it attach to the chassis? How best to attach the exterior plastic to the frame? How do I streamline the attachment hardware when handling multiple components?

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4.2 Short Inserts

The chart below works best when designing for short inserts.

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4.2 Regular Inserts

The chart below works best when designing for regular inserts.

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4.2 Flanged Inserts

The chart below works well when designing for flanged inserts.

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4.3 Boss Design for Flanged Inserts

The chart and boss design diagram works best when designing the layout for the flanged insert sizes listed. For unflanged inserts, eliminate the counter bore portion of the hole.

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4.4 Captive Screws

Screws thread through minor dia. hole in plastic Outer counterbore for screw head Inner counterbore for threaded portion of screw shank

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5.0 Finish Considerations

The Right Color Makes Your Product Shine ThermoFab executes all painting in-house to ensure maximum control over color, gloss, and texture. For the exterior color, we can color match using your color sample chip or specification. To ensure the right color is applied every time, ThermoFab uses Dupont Spectramaster.

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5.1 Paint Finish

Detail and Color let your products stand out from the crowd!
EMI/RFI spray shielding solutions Skys-the-limit design options Incredible detailing Custom paint processes Unique detail

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5.2 Min/Max Chips

Min/Max Paint Chips are used for color/texture/gloss level criteria. Each chip is divided in half. One half is the minimum; the other half is the maximum. These chips are kept by ThermoFab and the client so that each lot falls within the acceptable min/max range.

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5.3 Paint Lines for Two-Tone Parts

.03 wide by .03 deep groove at paint line for masking.

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5.4 Logo Artwork Design

Logo Design: Branding, Branding, and Branding! Line art is required for traditional screen printing. However, we have a machine that can print photographic images onto components, but the part must be no more than 2" thick. Gradients are not recommended because each color is screened individually onto a part. However, dot patterns in the screens may be used to mimic the look of a gradient. The result is a pixilated image that is best viewed from afar. Vector Artwork: If you have vector-based artwork from any of the file types listed below, the DPI doesn't matter. But if it is raster-based, a higher DPI will produce a better look. Preferred Files: Adobe Illustrator, Photoshop, Acrobat, and Distiller (.pdf, .eps, .ai, .ps, .psd), as well as AutoCad (.dwg, .dxf), Corel Draw (.cdr), and Corel Photo (.cpt). (We do not accept JPEGs, GIFs, or bitmaps.)

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6.0 EMI Shielding

EMI shielding protects any electronic products inside your custom thermoformed enclosures from electromagnetic interference (EMI). ThermoFabs certified technique involves applying Electrodag 440, a conductive stable nickel coating. We always perform EMI shielding in-house to ensure protection of your sensitive components and reduce time to market (TTM).

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6.1 Nickel Coating

Green indicates shielded surfaces Protects electronic products inside your custom thermoformed enclosures from electromagnetic interference (EMI); you will need EMI shielding. Certified for Electrodag 440, a conductive stable nickel coating

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6.2 Gasketing
Gasketing can be added to the interior design of the part. EMI gasketing gives additional levels of protection when required. See examples below.
Knitted Wire Mesh EMI/RFI Shielding Tape is a double-layered strip of knitted wire mesh. It provides effective electromagnetic and radio frequency interference (EMI/RFI) shielding for electrical and electronic cable assemblies. Metallized Fabric Shielding Gasketing is a combination of a metallized, woven nylon cover over a foam core. It provides superior EMI/RFI shielding. Wire Mesh Over Elastomer Core Gasketing provides effective EMI/RFI shielding and environmental protection. With two layers of mesh over an elastomer, the elastomer under pressure protrudes through the mesh to give sealing protection.
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7.0 Quality Assurance

Quality You Can Count On ThermoFab is committed to staying ahead of the competition and helping you do the same. Quality is not just a department; it is an ongoing commitment to control, improvement, and innovation. From tooling to final delivery, ThermoFab has inspections throughout the process to ensure that the product you bring to market exceeds your expectations for detail, craftsmanship, and performance.
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7.1 CMM
We know that you are working on a tight time to market, so from the moment you contact us, we respond promptly and clearly to your questions and requests. When we review your files, we will not commit to manufacturing your product unless we know we can deliver a quality custom plastic enclosure within your tolerances and specifications.

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7.2 Exterior Finish Control

Paint Color Min/Max Chips for Process Control Logos Silk-screening Final Inspection

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Just A Few Satisfied Customers

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Thank You!

76 Walker Road, Shirley, Massachusetts 01464 USA T 978.425.2311 F 978.425.2305 www.thermofab.com

Custom Plastic Enclosures. Revolutionary Process.