I am often approached by companies or hobbyists who want to have custom enclosures manufactured. Since many of them have the same questions, I decided to write down the process we follow to create a case to customer specifications.
The most common scenario is someone saw an existing product in our shop, but wants to make some modifications - perhaps custom milled pockets in the front panel, an overall different size, or in some cases a different material.
The Process
In the simplest case, we ask for a 3D model in STEP format or a technical drawing, and if we see that the changes can be applied to an already pre-manufactured case, we may be able to immediately provide a rough cost estimate.
But most of the time, the customization requires creating a custom manufacturing process from scratch. In such a case, we develop a prototype. The general process is as follows:
- Design the case according to customer specifications, by creating or updating the 3D model provided by the customer for manufacturability. Every step of the way you get to see the revisions and can decide on the next steps to make sure everything is in line with your expectations.
- We design a manufacturing process. This includes developing a work holding method for the case in the CNC machine, a CAM program, and decisions about materials and finishes.
- Manufacture the prototype, and send it to the customer for review.
Based on the prototype, the customer provides feedback and if needed, we develop additional prototypes. Once the prototype is perfect, production starts.
Custom Enclosure Cost
Every customers' requirements are different, so a general cost estimate is hard to give. When we agree to work on a prototype, you are informed frequently (e.g. daily) about time spent and the status of the project, so you can steadily monitor any progress made.
Nevertheless, what follows is a recent example for a case made from american walnut (250 x 200 x 50 mm).
Prototype Cost
- Upfront cost: 100 Euro fixed. This cost is refunded if a prototype is finished and payed.
- Create a 3D model based on customer requirements: 1h, 75 Euro/h
- Creating the CAM and manufacturing process for making a prototype: 2h, 75 Euro/h
- Creating the prototype: 5h, 75 Euro/h
- Material cost (American Walnut AA quality): 70 Euro. Material cost is non-refundable once the material is ordered.
Total cost for the prototype: 670 Euro
Production Cost
Material cost per case (American Walnut AA quality): 70 Euro
Total production cost (2 cases ordered): Material cost + 90 Euro each = 320 Euro
Total production cost (10 cases ordered): Material cost + 50 Euro each = 1200 Euro
Non-refundable upfront payment before start of manufacturing: Material cost + 20% of manufacturing cost.