3D printing service for custom enclosures — electronics housings, sensor boxes, IoT devices.
Custom enclosures are one of the most common applications for our 3D printing service. Whether you are housing a PCB, protecting a sensor module, or building a complete IoT device shell, we produce enclosures with snap-fit closures, mounting bosses, cable pass-throughs, ventilation slots, and integrated features — all without tooling investment.
Challenges we solve
What custom enclosures teams need from a 3D printing service
Getting snap-fits right on the first print
Snap-fit clearances are typically 0.1–0.3mm — tight enough that material selection, print orientation, and dimensional accuracy all matter. Our SLA platform holds ±0.2mm, and our engineers review every snap-fit feature for proper clearance before building. This means your enclosure closes cleanly on the first try.
Thin walls with consistent thickness
Enclosures need uniform wall thickness for structural integrity and aesthetic quality. FDM can show wall variations on thin parts. SLA and MJF produce enclosures with more consistent wall thickness — critical for parts that will be painted, texured, or visible to end users.
Integrating mounting bosses and hardware features
Screw bosses, heat-set insert holes, cable pass-throughs, and PCB standoffs are standard enclosure features. We review every file to verify boss diameter, hole depth, and feature accessibility for the chosen print orientation. If a feature is at risk of failing during printing, we flag it before the build starts.
Moving from prototype to production enclosures
Prototype in Standard Resin for validation, then switch to Nylon PA12 on MJF for production — same snap-fit geometry, same mounting features, production-grade mechanical properties. One vendor from first prototype through production run.
Materials
Materials for custom enclosures
For prototype enclosures, Standard Resin on SLA gives you the smoothest surface (2 Ra μm) and tightest tolerances (±0.2mm) — ideal for snap-fit validation and client presentations. Tough 2K adds ABS-like impact resistance for drop testing. For production enclosures, MJF Nylon PA12 delivers consistent wall thickness and mechanical properties across batches. PETG on FDM is the most cost-effective option for functional enclosures at larger sizes (up to 360 × 360 × 360mm). Durable Resin handles enclosures with living hinges or repeated flex closures.
Standard Resin
SLA · Shore D 78
Smooth surface, fine detail. Good for visual prototypes and concept models.
Tough 2K
SLA · Shore D 76
ABS-like toughness with SLA detail. Functional prototypes that need impact resistance.
Nylon PA12
MJF · Shore D 73
Strong, lightweight, chemical resistant. The standard for functional end-use parts. Excellent fatigue resistance and consistent mechanical properties.
PETG
FDM · Shore D 74
Tough, chemical resistant, food-safe options. Good balance of strength and flexibility.
Durable Resin
SLA · Shore D 58
Polypropylene-like. Flexible, fatigue resistant. Good for snap fits and living hinges.
Common parts
What we build for custom enclosures
Built in our factory
Brooklyn, NY
How it works
Your project, step by step
Upload enclosure file
Upload your STEP or STL. Include PCB dimensions and mounting requirements if you want our team to verify fitment.
Design review
We check wall thickness, snap-fit clearances, boss diameters, and vent features. If anything needs adjustment, you get specific dimensional feedback.
Production
Enclosure printed on SLA, MJF, or FDM with orientation optimized for surface quality on visible faces and strength on structural features.
QA
Snap-fit closure verified. Mounting features checked. Dimensional inspection on critical interfaces.
Ship
Enclosures packed to prevent damage. NYC: next-day delivery. National: tracked shipping in 2–5 days.
FAQ
Frequently asked questions
What is the thinnest wall you can print on an enclosure?
SLA: 0.4mm minimum. MJF: 0.5mm minimum. FDM: 1.0mm minimum. For most enclosures, we recommend 1.2–2.0mm walls for structural integrity and consistent print quality.
Can you print enclosures with integrated snap-fits?
Yes. SLA and MJF both produce snap-fits with functional clearances. We review every snap-fit feature for proper interference and recommend adjustments if needed. Tough 2K and Durable Resin are the best materials for snap-fits that need repeated cycling.
Can you add heat-set inserts to the enclosure?
We print the enclosure with properly sized holes for heat-set inserts. Insert installation can be done by your assembly team or discussed as a post-processing step. Hole diameter and depth are verified during file review.
What surface finish options are available for enclosures?
SLA Standard Resin delivers 2 Ra μm — smooth enough for painting or direct use. MJF has a matte, slightly textured finish. FDM shows layer lines that can be sanded smooth. We offer post-processing including sanding, priming, and painting for enclosures that need a finished appearance.
Can you produce enclosures in color?
FDM is available in multiple colors (white, black, gray, custom). SLA and MJF produce parts in a limited color range but can be painted to any color specification as a post-processing step.
Other applications
Rapid Prototyping
Functional prototypes in 2–3 business days. Test form, fit, and function before committing to tooling.
Production Parts
Production-grade 3D printed parts at volume — without tooling investment.
Hardware Development
One vendor from first prototype to production parts — no retooling, no requalifying.
Large Format 3D Printing
Single pieces up to 1200mm — or seamless multi-part assemblies at any scale.
Tooling & Fixtures
Custom jigs, fixtures, and assembly aids — delivered in days, not weeks.
Bridge Manufacturing
Ship real product now. Transition to injection molding when you are ready.
Replacement & Spare Parts
Reproduce legacy parts, replace obsolete components, and eliminate spare parts inventory.
Low Volume Manufacturing
Manufacture 10 to 5,000 parts without tooling — scale up or down order by order.
Presentation Models & Props
Presentation-quality models, trade show props, and display pieces — finished and delivered on time.
Casting Patterns
3D printed casting patterns — clean burnout, fine detail, no traditional pattern tooling.
Medical & Anatomical Models
Anatomical models, surgical planning aids, and medical training tools — dimensionally accurate.
End-Use Consumer Products
Ship real products to real customers — without injection mold tooling.
Design Verification & Testing
DVT and EVT builds in production-representative materials — validate before you tool.
Product Design Validation
Test form, fit, and function with production-grade materials before committing to tooling.
Investor Samples
Presentation-quality parts that look and feel like the final product — built for boardrooms, pitch decks, and demo days.
Pre-Production Testing
Validate tolerances, material behavior, and assembly flow at low volume before committing to production.
Jigs and Fixtures
Custom tooling for your production line — printed and delivered in days, not weeks.
End-Use Production Parts
Parts that go directly into products your customers buy and use — not prototypes, not samples.
Supply Chain Supplementation
Fill gaps in your supply chain without retooling or waiting months for overseas shipments.
Low-Volume Serial Production
Hundreds to thousands of identical parts — no MOQ from a mold shop, no tooling investment.
Replacement Parts Programs
On-demand spares for legacy and current products — without warehousing inventory.
Architectural Models
Site models, facade studies, and presentation pieces at true scale — printed whole or assembled seamless.
Trade Show Builds
Oversized displays and product replicas built to withstand transport and handling — show-ready finish.
Industrial Housings and Enclosures
Full-size prototypes of panels, covers, and housings — validate before committing to sheet metal or tooling.
Tooling and Molds
Large-format mold masters and lay-up tools — printed faster than machined.
Props and Set Pieces
Camera-ready props for film, TV, and commercial production — on tight timelines.
Wind Tunnel Models
Dimensionally accurate aerodynamic test models at scale — smooth surfaces, tight tolerances.
Legacy Part Replacement
Reverse-engineer and reproduce discontinued parts from scans or drawings — no original tooling needed.
Part Consolidation
Combine multi-part assemblies into single printed components — fewer parts, fewer failure points.
Lightweighting
Topology optimization and lattice structures — cut weight without cutting strength.
Manufacturability Analysis
Evaluate your design for printability before committing to a production run.
Scan-to-CAD
Point cloud in, watertight solid out — production-ready CAD from any 3D scan.
Tooling Design
Custom jigs, fixtures, and mold masters — designed from scratch for additive manufacturing.
Fixture Optimization
Redesign production fixtures to reduce weight, improve ergonomics, and speed up assembly.
Insights
Related reading
Materials
Choosing Materials for 3D Printing: PETG vs ABS
A detailed comparison of PETG and ABS for 3D printing, covering ease of printing, strength, chemical resistance, cost, speed, post-processing, and environmental impact.
Materials
Choosing Materials for 3D Printing: PETG vs PLA
A comprehensive guide comparing PETG and PLA for 3D printing, analyzing strength, durability, chemical resistance, cost, printing speed, and real-world applications.
Design
Practical DfAM Strategies to Help You Save on 3D Printing
Proven Design for Additive Manufacturing strategies to reduce 3D printing costs, including lightweighting, hollowing, orientation optimization, and smart batching.
Plan Your Project
Tools to plan your build
Check shipping transit times, estimate lead times by technology, and review design guidelines before you upload — so your parts print right the first time.
Check Transit Time
Enter your zip code to see how fast parts arrive from our Brooklyn facility.
Ready to start your custom enclosures project?
Upload your CAD file and get a quote in minutes — or talk to our engineers about your next production run.