Situation and challenge

The startup founder came with a rough 3D enclosure model for an IoT device. The model was built in an online tool and was not ready for printing - electronics tolerances were missing, connector holes were misplaced, and the design was not optimized for FDM.

The investor presentation was in 3 weeks, and the customer needed a functional, not only visual prototype - the enclosure had to securely hold electronics and open/close reliably.

FDM 3D printed product enclosure prototype – PETG
Functional IoT enclosure prototype in PETG – iteration 3, ready for investor presentation

Our solution

We started with a technical review and identified all critical model issues. In Autodesk Inventor, we applied updates: press-fit tolerances, corrected hole positions, and reinforced wall sections in stressed areas.

We printed the first iteration in PETG - a suitable material for functional prototypes with good durability and dimensional stability. The customer tested electronics fit and requested 6 concrete changes. Iterations two and three followed in 3-4 day cycles.

Why 3 iterations?
In product development, iterations are normal - not a failure. Each version reveals new improvements, which is exactly the purpose of prototyping. The key is to keep iterations fast and cost-efficient.

Outcome

The third enclosure version met all requirements - electronics fit precisely, the housing opened correctly, and all holes were in the right positions. The customer went to the investor presentation with a working device.

  • Number of iterations: 3 verzie za 14 days
  • Material: PETG - functional prototype
  • Assembly-hole tolerance: ±0.2 mm
  • Time per iteration: 3-4 business days including model updates

After successful fundraising, the customer continued with MATERIA on pre-production model preparation.