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03 / 09

Product Design

INFINIA / 2024

Electronic
Protection
Box

Electronic Protection Box final render with its bent aluminium enclosure and dark end panel
Electronic Protection Box — Adaptable enclosure for electronic cards

Overview

Electronic Protection Box is an adaptable enclosure for electronic cards, developed as a practical alternative to fixed-size off-the-shelf products. Its low-cost construction supports rapid production and dimensional changes without dedicated mould tooling.

Discipline

Product Design

Developed At

INFINIA

Demand

Customizable, Fast, Low-Cost Production

Schedule

One Week

Electronic Protection Box design process from research and ideation to development and prototype
Research · Ideation · Product development · Prototype

Project Direction

The one-week development process moved from market research and form exploration to production detailing and a functional physical prototype.

Research board examining electronic enclosures, aluminium construction and bent sheet-metal forms
Market, material and production research

Research

Existing electronic enclosures were reviewed around material, assembly and manufacturing logic. Aluminium bending emerged as a direct route to a smart, rugged and practical product that could be produced without mould investment.

Form sketches exploring alternative folded sheet-metal enclosure configurations
Bent-sheet form studies
Developed Electronic Protection Box render showing the light outer shell and dark internal layer
Developed product direction

Three-Part Architecture

The enclosure is organised into three functional layers: a dark lower mounting surface, a 3D-printed central carrier that secures the PCB with inserts, and a clean light-coloured upper shell that gives the product its precise technological character.

Exploded Electronic Protection Box render showing the aluminium shell, circuit board, carrier and base
Outer shell, PCB carrier and mounting base
Technical exploded views of the Electronic Protection Box components and PCB assembly
Component construction and assembly logic

Production Development

The metal components were designed for cutting and bending from 2 mm aluminium sheet, selected for its cost and forming suitability. Once the PCB was fixed, port openings were positioned so they could be cut into the enclosure during production.

Electronic Protection Box prototype with bent metal parts, PCB and 3D-printed internal carrier
First physical prototype and internal carrier

Prototype

A full physical prototype brought the bent aluminium parts, electronic board and 3D-printed carrier together, allowing the fit, fastening points and assembly sequence to be evaluated directly.

Electronic Protection Box prototype showing separated and assembled anodised enclosure parts
Anodised component finish and assembled enclosure

Surface Finish

Black and grey anodised finishes were tested for durability and scratch resistance. When the upper surface did not achieve the required clean appearance, it was refinished with powder coating.

Completed INFINIA Electronic Protection Box prototype with powder-coated upper shell
Completed prototype — powder-coated upper surface