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Authorized Client Case Study

Precision Fabrication
Medical Device Enclosure

Precision sheet metal fabrication for a medical-device prototype enclosure. Tight tolerances, complex bends, and durable powder coating for agreed cleaning and cosmetic review.

Project Overview

Industry
Medical-device prototype
Material
Aluminum 5052
Thickness
1.5mm & 2.0mm
Process
Laser Cut & Bend
Finish
Antimicrobial Powder
Standards
Medical prototype documentation controls

The Challenge

"Medical-device enclosure prototypes often need clean cosmetics, dimensional control for internal PCB mounts, and surface finishes that can be reviewed against agreed cleaning and cosmetic requirements."

Critical Requirements

  • Complex EMI Shielding: Precision folded seams to prevent electromagnetic interference for sensitive diagnostic components.
  • Deburred edges: Edges and corners were radiused to support safe handling during prototype review and assembly checks.
  • Cleanable finish: A smooth powder coating was selected against the buyer's cleaning and cosmetic requirements.

Our Execution

We utilized our dedicated sheet metal line, implementing customized press brake tooling and a meticulous finishing protocol.

1

Fiber Laser Cutting & Punching

Panels were cut using high-speed fiber lasers for perfectly clean edges, followed by CNC punching for precise ventilation louvers that prevent liquid ingress.

2

Precision Bending & Welding

We used multi-axis CNC press brakes to execute tight interlocking bends. Corners were seamlessly TIG welded and ground completely flush by expert technicians prior to coating, creating the illusion of a solid continuous shell.

3

Medical Powder Coating & Silkscreen

After chemical conversion coating for adhesion, the enclosures received a durable white powder coat, followed by precision silkscreening for clear operator instructions and branding.

Technical Highlights

  • Laser Cutting (Fiber)
  • CNC Press Brake Bending
  • TIG Corner Welding
  • Durable Powder Coating
  • Silkscreen Printing

Building device enclosures?

We help define documentation and finish requirements for regulated-product prototypes during RFQ.

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Evidence basis

Engineering evidence record

Regulated-product enclosure prototype record. This public case summary is based on anonymized RFQ notes, engineering review, inspection planning, and packing handoff records; customer-sensitive details removed.

Last reviewed: 2026-07-01
Customer industry
Medical-device prototype / regulated-product hardware; customer-sensitive details removed.
Part use
Sheet-metal enclosure used for fit, assembly, finish, and documentation review before production decisions.
Quantity
Prototype batch for engineering review; not presented as a certified medical-device production run.
Material
Aluminum 5052 sheet material and thickness confirmed from RFQ notes and approved drawings.
Process
Laser cutting, bending, welding, deburring, powder coating, and packing review.
Critical dimensions / tolerances
PCB mounting points, enclosure seams, bend offsets, lid fit, and visible cosmetic surfaces.
Surface finish
Powder coating reviewed against agreed color, texture, edge coverage, and cleaning/cosmetic expectations.
Max manufacturing risk
Bend accumulation and coating thickness can affect lid fit, screw alignment, and internal clearance.
DFM before / after
Before: bend stack-up and coating clearance were not fully separated. After: bend sequence, masking, coating buildup, and inspection datums were reviewed.
Inspection method
Dimensional report, assembly fit check, finish photos, and material traceability can be prepared when agreed during RFQ.
Shipping documents
Commercial invoice, packing list, protective packaging photos, and scoped inspection documents.
Lead time / result
Prototype route supports engineering validation; regulatory approval and device certification are outside the default shipment scope.
Customer authorization
Representative case shared with customer-sensitive details removed; public photo use is limited to approved imagery.
Evidence basis
Based on anonymized RFQ notes, DFM review, inspection planning, and packing handoff records. Last reviewed: 2026-07-01.
Quote boundary: This case does not imply default CMM, FAI, certification, regulatory approval, or production readiness. Inspection method, shipping documents, customer authorization, and documentation package must be agreed during RFQ.
This case study is shared as a representative manufacturing example with customer-sensitive details removed. All intellectual property rights remain with the original owner.
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