• 300+
    Enclosures designed
  • 15+
    Years experience
  • $2.5M+
    Saved in mistakes avoided
The 7 Mistakes Costing You Thousands
  • ❌ Mistake #1: Designing Before PCB is Final
    "The PCB is 95% done, let's start the case!" Two weeks later: connector moved 5mm for routing optimization. Beautiful enclosure now useless.

    Cost: $3,000-$8,000 in redesign + 2-4 week delay
  • ❌ Mistake #2: Mistake #2: Ignoring Thermal Management
    Case looks amazing. First power-on test: device throttles at 40% load. Surface temp: 85°C. Emergency redesign needed.

    Cost: $5,000-$15,000 mold modifications + 4-8 week delay
  • ❌ Mistake #3: Assembly Sequence Not Planned
    Prototype arrives. Try to assemble... PCB needs to go in first, but display connector blocks installation. Infinite loop.

    Cost: $20,000+ in extra assembly labor (6 min instead of 2 min × 10K units)
  • ❌ Mistake #4: Tolerance Stack-up Ignored
    CAD shows 0.5mm gap. Production samples: 3.5mm gap on some units, interference on others. "Why doesn't it look like the render?"

    Cost: $2,000-$8,000 per mold revision × multiple revisions
  • ❌ Mistake #5: Material by Looks Not Requirements
    "We want ABS because it looks nice." Product needs UL94-V0 for safety cert. ABS isn't rated. Oops.

    Cost: $15,000-$30,000 lost on wrong tooling + 6-8 week delay
  • ❌ Mistake Mistake #6: Skipping Prototype to "Save Time"
    "Prototype costs $5K, let's just go to production tooling." Assembly issues discovered in production. Need mold modifications.

    Cost: $20,000-$60,000 (4x-12x more than prototype would cost)
  • ❌ Mistake #7: Cheapest Supplier Wins
    Quote shopping by price alone. Lowest bidder chosen. Sink marks everywhere. Assembly difficult. Delayed launch.

    Cost: Varies - Delayed revenue + reputation damage + redesign
What's Inside the Guide
Production Method Guide
Decision tree by volume
Cost comparison table
Timeline expectations
When to use each method
Injection Molding Basics
Wall thickness rules
Draft angle requirements
Rib and boss design
Common defects prevention
Joining Methods
Screws vs snap-fits vs welding
When to use each
Assembly considerations
Cost implications
Common Mistakes
All 7 mistakes explained
Real cost breakdowns
Prevention strategies
When exceptions are OK
Supplier Selection
How to evaluate manufacturers
Questions to ask
Red flags to watch for
China vs local production
What Engineers Say
“
This guide saved us at least $15K on our first enclosure project. The tolerance stack-up section alone was worth it — we would have made that exact mistake."
Hardware Engineer, IoT Startup
“
Finally, someone explains DFM in plain English. I've been sending this guide to every hardware founder I mentor
Product Manager
“
Wish I had this guide 3 years ago. Would have saved me two failed mold attempts ($35K total). The design sequence section is gold
CEO & Founder
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From Encadra | 15+ years experience | 300+ enclosures designed | encadra.com
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