TIM INFINITY / PROJECT
Custom Thermoformed ABS Enclosure
For an industrial electronic device, TIM Infinity developed a custom external enclosure from 3 mm white ABS, manufactured by thermoforming.
The starting point was a computer render of the device. The shape and production geometry of the plastic enclosure were developed from the visual concept, followed by design and manufacture of the corresponding tool.
After the prototype had been manufactured, the enclosure was tested on the actual industrial device. Once the geometry was approved, thermoforming, final trimming and a production run of 350 pieces were completed.
01
Project requirement
The task was to develop a physical plastic enclosure for a specific industrial device from a computer render.
The render defined the visual direction of the product, but a manufacturable geometry had to be developed that would match the appearance and dimensions of the device while also being suitable for thermoforming.
The project therefore involved more than manufacturing an existing part: it required development of a custom plastic enclosure from the initial visual concept through to a functional prototype and production run.
Custom plastic parts02
Shape and geometry development
The supplied render was used to develop the shape, proportions, radii and transitions of the future enclosure.
It was particularly important to align the appearance of the part with the manufacturing technology so that the geometry could be produced reliably from 3 mm ABS sheet.
Areas for final trimming after thermoforming were also defined during development so that the finished part would match its intended position on the device.
03
Tooling design and manufacture
Once the product geometry had been approved, dedicated thermoforming tooling was designed.
The tool was developed to the final enclosure geometry and matched to forming depth, radii and transitions on the part.
After the tool had been manufactured, the first functional prototype was produced.
Thermoforming tooling design and manufacture04
Prototype and testing on the industrial device
A prototype enclosure was produced before series manufacturing began.
The prototype was fitted to the relevant industrial device to check geometry, dimensions, part position and fit with the rest of the product.
This stage allowed the solution to be verified in the real application before series manufacturing was approved.
05
Thermoforming 3 mm white ABS
The enclosure was manufactured from 3 mm white ABS.
The ABS sheet was heated and thermoformed over the prepared tool so that it took on the defined three-dimensional geometry of the enclosure.
After forming, final trimming was carried out to the designed contour, converting the thermoformed blank into a finished enclosure ready for its intended application.
Thermoforming & Vacuum Forming ABS and other thermoforming materials06
Production run of 350 pieces
After the prototype had been tested and approved, a production run of 350 pieces was completed.
The defined tooling and thermoforming process enabled the same geometry to be repeated across the production run, and every part underwent final trimming after forming.
The project covered the complete path from visual concept and shape development to a functional part and series manufacturing.
SEND AN ENQUIRY
Do you need an enclosure, cover or another plastic part for a device?
If you have a computer render, digital 3D model, technical drawing, existing device or a defined design concept, send the available information for a feasibility assessment.
TIM Infinity can cover product development, tooling design and manufacture, prototyping, thermoforming and production of the required quantity of plastic parts.
Send an enquiry