Embedded-Electronics Enclosure Mechanical Design

I need a complete mechanical design for a small embedded-electronics enclosure that can go straight to tooling. Plastic is the primary material, so every feature has to respect injection-moulding constraints—draft angles, uniform wall thickness, living hinges or snap-fits where appropriate, and clear guidance on gate and ejector placement. Although the first production run will be plastic, I may commission a metal spin-off later and would prefer that version to carry a polished finish, so keep that in mind when you define radii and surface transitions. The unit must keep fine dust out of the electronics without relying on messy gaskets; smart labyrinths, tongue-and-groove joints, or over-moulded seals are all welcome solutions. At the same time, the design has to stay compact and serviceable: PCB standoffs, button light-pipes, venting for heat, and discreet USB/power openings will all be needed. Deliverables • 3D CAD (STEP + native format) ready for mould-flow review • 2D manufacturing drawings with tolerances, finish call-outs, and assembly notes • Exploded view/assembly guide and a short design-for-manufacture rationale Acceptance criteria • Parts open/close repeatedly without tool clashes or screw stripping • Passes basic dust-ingress test (IP5X target) in simulation or checklist form • All draft angles ≥1° and no wall thicker than 3 mm without coring If you’ve shipped similar plastic enclosures and can balance DFM with a clean consumer look, let’s talk.