Case study · custom electronics enclosure

Custom air quality sensor enclosure

This was not designed as a generic box. The enclosure was built around the actual electronics and component layout, with openings and details that had to match the device.

Bearhill Lab · Zagreb, Croatia
The brief

An enclosure designed around existing electronics

The starting point was the real electronics layout inside the device. The enclosure needed to keep the components organised while maintaining access to the USB-C connectors and providing a defined position for the LED indicator.

In addition to the base and main lid, a transparent outer cover was developed as part of the solution. The result is a cleaner, enclosed device without changing the functional component layout.

Key custom details

What had to be designed to fit

Component layout

Internal space follows the actual electronics rather than forcing the hardware into an off-the-shelf box.

USB-C openings

The connector positions were included in the enclosure geometry so they remain accessible after assembly.

LED position

A defined location for the visible LED element was designed in from the start instead of being added afterwards.

Transparent cover

A separate transparent outer element was developed as part of the complete enclosure concept.

Project photos

The implemented solution

Where this approach fits

From one prototype to a repeatable small batch

A custom enclosure is useful when a standard commercial box does not match the electronics, connectors, component layout or desired form. Bearhill Lab can start from measurements, existing electronics, a sketch or a device description, build the first functional version and adapt the model for additional units if needed.

More about prototypes and small batches →

Have a PCB, sensor or electronics project?

We can assess an enclosure around the actual components

Send photos, dimensions, connector positions and approximate quantity to [email protected].

Email: [email protected]

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