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Designing electronic equipment for medical environments brings a different set of expectations.
A medical device manufacturer developing compact electronic systems for mobile medical applications approached Mech Power while reviewing the performance of an existing plastic enclosure already in use. The actual enclosure met original functional requirements, however the problems with mounting started to show up when the device was tested in real-world operating conditions.
What started as a review of mounting stability soon evolved into a broader enclosure engineering exercise, focused on improving structural strength, interface alignment, and overall reliability for use in moving medical environments.
The Challenge: Reliability Issues with a Plastic Medical Enclosure
The existing plastic enclosure faced mounting instability, display alignment issues, and limited structural rigidity when used in vibration-prone, mobile medical environments.
During real-world use, the plastic enclosure showed several limitations:
- Weak mounting points caused instability during vibration
- Display alignment shifted during movement
- Plastic enclosure lacked sufficient rigidity for continuous motion
- Limited scope for precise cutouts and interface placement
The customer required a more reliable enclosure solution, with improved stability and display performance, without increasing overall size.
Design Requirement: Transition from Plastic to Metal Enclosure
The requirement went beyond changing materials.
Switching from a plastic to a metal enclosure requires a complete redesign of the enclosure layout, mounting strategy and interface placement. The enclosure needed to maintain its compact size while providing improved structural strength and vibration resistance.
At the same time, the display interface required precise alignment to ensure consistent visibility during operation.
Mech Power’s Solution: Hybrid Metal and 3D Printed Enclosure Design
Mech Power proposed a hybrid enclosure design, combining the strengths of metal fabrication and 3D printing.
The solution included:
- A mild steel enclosure to improve rigidity, mounting strength, and vibration resistance
- A 3D printed display bezel (FDM) to maintain accurate display alignment and controlled tolerances
This approach allowed structural performance to be handled by metal, while dimensional precision around the display was achieved using 3D printing.
If you’re working on a product that involves custom parts, enclosures, or a hybrid manufacturing approach, we supports different ways to get started.
For 3D printed parts, you can explore instant pricing directly through our Instant Quote workflow.
For sheet metal fabrication and other custom builds, you can share your requirements with our team, who will review the details and recommend the right manufacturing approach.
Technical Specifications
- Enclosure/Part Material: Mild Steel
- Display Bezel: 3D Printed (FDM)
- Sheet Thickness: 1.5 mm
Overall Enclosure Size:
- Length: 200 mm
- Width: 100 mm
- Height: 135 mm
Custom cutouts were integrated for the display and interface elements, ensuring functional access without compromising enclosure strength.
Results: Improved Stability and Display Performance
The hybrid enclosure delivered clear performance improvements compared to the earlier plastic design:
- ~85% improvement in structural stability during vibration and movement
- ~70% improvement in display alignment consistency
- Clear and stable display visibility during mobile operation
- Improved durability suitable for long-term medical use
The enclosure performed reliably in motion-based environments where the earlier plastic housing had limitations.
Conclusion: Why Hybrid Enclosure Design Matters in Medical Devices
This case study illustrates how hybrid enclosure design can enhance reliability in medical applications.
By combining metal enclosure fabrication with 3D printed Display Bezel, the customer achieved a balanced solution that addressed both structural strength and precision requirements.
The final enclosure was better suited for real-world medical mobility environments while remaining compact and functional.
Want to explore how a hybrid enclosure approach could work for your application?
Contact us to share your requirements.