Water-Resistant Innovation: Consumer Electronics Enclosure Design

Project Background

A leading consumer electronics manufacturer approached us to develop a water-resistant enclosure for their next-generation portable device. The project required balancing multiple competing requirements:

• IPX7 water resistance rating requirement
• Premium look and feel with minimal seam lines
• Efficient heat dissipation for internal components
• High-volume production capability (500K units/year)
• Cost-effective design for competitive market positioning

Technical Challenges

Water Resistance Design

• Complex geometry requiring multiple seal interfaces
• Port protection while maintaining accessibility
• Material selection for long-term seal integrity
• Testing and validation procedures development

Thermal Management

• Heat dissipation through sealed enclosure
• Thermal interface material selection
• Airflow optimization within constraints
• Temperature monitoring system integration

Manufacturing Considerations

• Multi-shot molding process development
• Assembly automation requirements
• Quality control and testing procedures
• Production cycle time optimization

Solution Development

Implementation & Testing

Rigorous testing and validation procedures were implemented to ensure design success:

• Environmental testing chamber validation
• Accelerated life cycle testing
• Drop and impact resistance verification
• Thermal performance monitoring
• Production line quality control procedures

Results & Impact

The project achieved all key objectives and established new benchmarks:

• Successful IPX7 certification achieved
• 15% reduction in production cycle time
• 8% material cost optimization
• Zero field failures reported since launch
• Positive user feedback on design and durability

"ATI Engineers delivered an exceptional solution that exceeded our expectations. The water-resistant design has become a key differentiator for our product in the market."