Your PCB works perfectly. But does It look like a 2015 prototype?

Industrial design for electronics enclosures: from sketch to production-ready CAD in 10–21 days. We create devices you won't be ashamed to show investors or send to series production.
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What a professional product looks like
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What the challenges you face?
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From CAD to finished enclosure
A transparent look at silicone casting - including design errors that lead to mold failure, rework, and wasted budget.
Factory receives your CAD and reviews it
The manufacturer checks whether the enclosure dimensions in the drawings match the real geometry.
A prototype is printed and checked for assembly
In reality, many factories don’t care if parts actually assemble — it’s the client’s problem.

Good manufacturers still check assembly, clearances, flexibility, and tolerances.
A master model is produced

Note: a master model typically lasts no more than 6 months.
Over time it can absorb moisture and deform.
A silicone mold is made from the master model

With proper design, one silicone mold can produce up to 25 identical parts. After that, repeated opening cycles distort the mold and reduce quality.
Important: part design matters

At this stage, correct part design is critical. It affects demolding, material flow, and defects caused by shrinkage (sink marks).
Proper design

What proper design means

A properly designed part has draft angles. Without them, the part cannot be removed freely and will tear the silicone mold.
Costly mistake

This is where you lose money

Instead of 25 parts per mold, you may get only 3. Snap-fits are another common mistake — silicone molds have no sliding cores. Producing snap-fits this way is not possible.
Mold failure

No draft angles - mold tears apart

Design errors are extremely common.
People design enclosures without understanding the manufacturing process — and pay for it later.
Draft angles

Part designed with proper draft angles

For silicone casting, the part must be designed around the demolding direction. You cannot “just pull it out” — experience matters.

Also important: a part designed for silicone casting almost never works for injection molding — unless this was planned from the start.
Silicone is poured into the mold

Materials are mostly imported, so cost depends on exchange rates.
Air bubbles are removed in a degassing chamber

Air bubbles are unavoidable in polyurethane casting, especially in thick sections. A good contractor positions the part so bubbles don’t appear on visible surfaces.
The silicone mold is cut into parts

The mold is cut with a wavy pattern to ensure precise alignment. Straight cuts almost always cause misalignment.
Polyurethane is poured

Common issues at this stage:
  • contamination
  • uneven pigmentation
  • missing UV stabilizers
Excess material is removed

  • Runners and excess polyurethane are trimmed immediately after casting.
The silicone mold is opened

  • Risk: if the process is done incorrectly, the mold may not open without damage.
Post-processing

  • Gate marks are finished and surface defects are cleaned up.
Finished product

  • That’s it — the enclosure is ready.
Congratulations! You’ve reached the final step.

You can now get our free guide on enclosure design and manufacturing.
Where should we send it?

Want to estimate the cost on your own?

We’ll share the same pricing methodology used by manufacturing companies.
The point is this: a table where we’ve collected data from 15 real plastic enclosures for electronic devices.

You will be able to:


  • Roughly estimate how much “a plastic enclosure like this” would cost — similar to yours.
  • Understand how much time is required for design and production.
  • Compare unit cost at different volumes — from 1 to 200,000 units.
  • Get a high-level view of the total budget required.
Register to get access to the table
Register to get access to the table

How much should I budget for mockups and prototyping? What timelines should I expect?

If you want to understand how much a mockup or prototype will cost, the first step is to choose the manufacturing technology.
For example, producing a mockup using FDM 3D printing can take just a few hours (for a small device) and cost a few thousand rubles. A prototype made by polyurethane casting in silicone molds, on the other hand, typically costs tens of thousands of rubles and takes several days to produce.
Manufacturing a prototype from reinforced glass-filled polyamide costs about $5,000.
Below are examples of serial production costs. Choose the category you’re interested in.
Small-batch production
II. Plastic parts manufacturing
III. Plastic enclosure manufacturing
IV. Sheet metal enclosure manufacturing
V. Metal enclosure manufacturing using die casting
VI. Aluminum parts manufacturing by extrusion
Need document samples?

Download free Enclosure Design Guide

Practical guide to designing enclosures for electronics hardware. Based on 15+ years of experience and 200+ completed projects.

What's inside:
- 4 manufacturing methods compared
- Common design mistakes to avoid
- Cost estimation framework
- Real project examples
Free download. No spam, just occasional hardware design tips.
FAQ
You can stop the progress of work and return the remaining unspent funds. All the results of the work accepted by this moment will remain yours, and a link to the archive with them will be added to the chat.
Artem Smirnov
Industrial Designer
Head of Development Department
Evgeny Arakas
Lead designer
Anton Romanyuk
Andrey Vostrikov
... and others – technical writers, engineers, technologists, 3D modelers – Red Ring Design is constantly growing and evolving.
We always focus on solving the client’s core challenge: their product must sell well, cost less to manufacture, and outperform the competition
3D Modeler
Vladimir Panchenko
Alexey Benner
Industrial Designer
Red Ring Design, LLC
Tell us about your hardware. We'll send you a project timeline and cost estimate within 48 hours.

We'll review your project and send you a detailed estimate. Your information stays confidential.
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Andrey Vostrikov
Industrial designer, project lead

I’m Andrey Vostrikov, an industrial designer with over 15 years of hands-on experience.
Let’s discuss your task — how to solve project challenges and find the most practical solution. I work with real numbers and facts. Formlab has designed enclosures for a wide range of products, and over the years we’ve built a solid knowledge base on timelines, costs, manufacturing methods, factories, and technologies.
A 20–30 minute conversation can save you weeks of work and research.
Just choose a convenient time slot that works for you.