Hi, Guys!

At the moment, we have developed the following design. A CAD model was created based on the PCB and the design. The overall dimensions have been reduced to a minimum. The outer design is worked out, and internal refinements are foreseen. The housing will consist of two parts – upper and lower – and will be joined using ultrasonic welding. On top, there will be a silicone pad, which is planned to be glued. The housing will be non-disassemblable.

Download 3d in STEP

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  1. Check the dimensions to ensure that all necessary electronic components, including the antenna, can be accommodated, even though I used the CAD model of the PCB as a reference.
  2. Evaluate the model in terms of manufacturability and the possibility of adding elements for securing the internal components, slots for buttons and LEDs, inscriptions, etc.
  3. Determine the most rational way to finalize the model. Is it better to do this on your side with my comments and recommendations, or should I make some further modifications? Perhaps you already have proven technological solutions. It is important to determine the most efficient format of cooperation.
  4. Confirm the feasibility of ultrasonic welding for this model.
  5. Clarify the technological possibility at your factory to make transparent areas on the upper silicone part, similar to JBL speakers (see picture). Under this part, there will be a wall designed in a similar way to your current model with a slot for pressing buttons.
  6. The housing must be water-resistant. For this purpose, we are making plastic plugs for the USB and SIM ports. The plugs will have a groove for a rubber ring. I see this design as the most reliable and easiest to adapt. To ensure the plugs fit with the required tightness, we will need to adjust the groove depth and ring diameter. Most likely, the rubber ring will be 1 mm. We plan to vary the fit by adjusting the groove depth. For this, it may be necessary to produce several samples with slight variations in size. Do you have the ability to make prototypes quickly enough to find the optimal combination of dimensions and fits? Perhaps you have a standard range of rubber rings in terms of length?
  7. Questions regarding the material can probably be omitted for now, if they can be resolved later. But overall, we can take the model you already produced as a reference.

Example for transparent LED parts

Example for transparent LED parts

Rubber rings

Rubber rings