A wall-mounted, electric car charging station doesn’t sound like it’d require the most exciting or complicated enclosure. This was pretty much the assumption [Mastro Gippo] and his team started out with when they decided to turn what came back from a product designer into a real enclosure for the ‘Prism’ charging hardware they had developed. As it turned out, the enclosure proved to be the most challenging part of the project.
The first thought was to make a cheap, simple prototype enclosure for integration testing. This led them through trying out FDM 3D printed enclosures, wooden enclosures, folded (glued) plastic enclosures, aluminium extruded enclosures, Zamac alloy enclosures, and finally the plastic injection molded enclosure they had been avoiding due to the high costs.
Even if it meant taking out a loan to cover the setup costs, the results really do speak for themselves with a well-integrated design and two really happy looking partners-in-business. It does make us wonder how projects lacking this kind of financial leeway can get professional-grade enclosures without breaking the proverbial bank.
FDM 3D printing is always getting better and with a lot of post-processing you can have one enclosure that looks great, but that doesn’t scale. Outsourcing it to a professional 3D printing company like Shapeways is better, but it’s still not injection-molding quality and if the product is successful you’ll eventually invert the cost/benefit you were shooting for in the first place. Where is the middle ground on great-looking enclosures? Please let us know your experiences and thoughts in the comments.