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An innovator in the agriculture IoT space approached Mech Power with a challenge familiar to many hardware startups. Their soil testing device, built to help farmers make data-driven decisions about soil health, looked promising on paper but faltered during field tests.
Mechanical fit issues, misaligned parts, and usability inconsistencies made the device unreliable. They needed a partner who could move fast, refine the design, and help them reach production readiness without compromising performance.
The Challenge
When our team first examined the prototype, several design and assembly needs were identified for improvement
- Gaps in the back body reduced rigidity and compromised sealing.
- PCB alignment mismatches led to loose and tilted placements.
- Screws near terminals created a risk of electrical shorts.
- A misaligned USB port limited sensor connection during tests.
- The push button jammed after use in a small detail, but critical in field conditions.
These weren’t cosmetic issues; they directly impacted functionality, user trust, and field performance. The customer needed a robust, fit-first prototype to validate their design before moving toward production.
Our Approach
At Mech Power, our focus was on making the device perform as intended. We began with a complete design validation, checking geometry, PCB clearances, and assembly interactions to uncover dimensional mismatches.
Once the analysis was complete, we shifted to 3D printing for quick iterations and precise testing.
Here’s What We Refined
- Strengthened Structure
Increased the base box wall thickness from 1.2 mm to 1.7 mm to improve rigidity and impact resistance. The enclosure now handles field use and vibration with greater stability. - Refined Sensor Housing
Reduced the sensor housing wall thickness from 2.5 mm to 2 mm for a cleaner fit, more consistent sensor alignment, and better material efficiency. - Improved Mounting Compatibility
Adjusted hole dimensions and added brass inserts to both the top covers, ensuring secure, repeatable fastening. Brass inserts were also introduced for the main PCB mounting points, improving long-term durability and preventing thread wear. - Enhanced Sealing
Modified rib geometries across the base and bottom cover to achieve uniform gasket compression. This change improved dust and moisture resistance, making the enclosure more reliable in field environments. - Validated PCB Mounting
Resolved mismatches between the 3D model and physical PCB to ensure accurate alignment and stable board positioning during testing.
Each update went through rapid 3D-printed iterations to confirm accuracy before production.
The redesigned enclosure was produced using high-precision FDM 3D printing in white ABS chosen for its strength, heat resistance, and smooth finish. With a 0.4 mm nozzle and 0.15 mm layer height, we achieved tight tolerances and clean surface quality, crucial for PCB alignment and sealing.
The entire re-design-to-validated prototype and post-processing cycle took about 4–5 days, completing the design-to-functional prototype within a week. Post-print inspection confirmed ±0.1 mm accuracy on PCB mounts, resulting in a perfectly aligned, rework-free prototype ready for production validation.
The Outcome
The final prototype passed all field and functional tests. After assembly and validation:
- PCB and port alignments were precise.
- Electrical tests confirmed zero shorting or interference.
- The push button worked flawlessly.
- The LED indicator was fully visible in sunlight.
These refinements allowed the startup to run successful soil data trials and move toward pilot manufacturing without mechanical issues.
The project did more than solve design problems—it restored momentum. The improved prototype helped the customer:
- Present a working proof of concept to investors and distributors.
- Cut design-to-field testing time by nearly 40%.
- Eliminate rework costs and improve early-stage efficiency.
Conclusion
This project shows how practical engineering and precise 3D printing can turn an early concept into a reliable, field-ready solution.
Through careful redesign and rapid prototyping, Mech Power transformed a flawed prototype into a validated, manufacturable enclosure—ready for real-world testing and small-batch production.
At Mech Power, every refinement serves one purpose: making your design work reliably and repeatedly. From dimensional validation to final assembly, we partner with innovators to turn promising ideas into production-ready products.