Sensor enclosure DFM review
A manufacturability review that cut part count from eleven to six and removed a costly secondary machining step.
- Year
- 2026
- Type
- Client project, DFM review
- Client
- Hardware startup (under NDA)
- Scope
- Review, redesign, supplier handover
The problem
A startup was preparing to order injection-mould tooling for an outdoor sensor enclosure. Quotes for tooling and assembly were well above their budget.
Inspiration and concept
Before suggesting changes, we mapped every part, every fastener and every assembly step, and priced each one with their supplier.
Sketches, prototypes and iterations
Three separate brackets were merged into features moulded into the base. Screw bosses were moved so both halves could be moulded without side actions.
A gasket that needed hand fitting became a groove for a standard O-ring.
Engineering and manufacturing decisions
- Uniform 2.5 mm wall thickness to reduce sink and warp.
- Draft added to all vertical faces.
- Snap-fit lid replaced four screws for the service cover.
Materials, processes and assembly
Glass-filled PC/ABS for UV resistance and stiffness outdoors.
The result
Part count went from eleven to six and assembly time fell from nine minutes to under four. The tooling quote dropped substantially, and the design went to production.
Challenges and lessons
The biggest savings came from parts the client had stopped noticing. Mapping the whole assembly before changing anything is now the first step in every review.
