What is Tool Free Enclosure Manufacturing?

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Tool free enclosure manufacturing enables the creation of an electrical enclosure without the need for traditional tooling and moulds. Using CNC machining, heat bending, and assembly processes borrowed from sheet-metal fabrication, we can produce enclosures from flat stock panels. This method eliminates expensive, tooling setups, allowing for rapid prototyping and production at any scale.

Tool free enclosure manufacturing enables the creation of an electrical enclosure without the need for traditional tooling and moulds. Using CNC machining, heat bending, and assembly processes borrowed from sheet-metal fabrication, we can produce enclosures from flat stock panels. This method eliminates expensive, tooling setups, allowing for rapid prototyping and production at any scale.

Key Technical Steps in the Process

  1. Design & CAD Input
    Begins from CAD models, 2D drawings, or even component samples. We collaborate throughout to refine fit, access, mounting features, and aesthetics.
  2. CNC Routing
    Flat plastic sheets (e.g. ABS, HIPS, polycarbonate UL94‑V0) are precision-cut to form panels with apertures, vents, and joint profiles (e.g. tongue-and-groove) via CNC routers
  3. Scoring & Heat Bending
    Pre-scored V-shaped cuts allow thermally bending panels along precise angles using heated bending tools or press brakes
  4. Boss & Insert Preparation
    Metal inserts are installed into routed recesses to provide robust fixing for components and PCBs
  5. Solvent-Weld Assembly
    Panels are assembled and permanently bonded using solvent welding, creating seamless corners and joints
  6. Finishing & Customisation
    Final touches—Painting, digital printing—are completed to finalise the customer product.

Advantages compared to traditional tooling

Speed to market – Without the lead time for tool manufacture we can rapidly deliver prototypes and production quantities

Cost efficient for low to mid volumes – Avoiding the upfront tooling costs make small to medium production batches cost effective enabling customers to test the water with new products to gauge product demand before proceeding to tooling and moulding.

Design Flexibility – Whilst tools can be adjusted this does come with limitations, tool free enclosure manufacturing allows sizes and cutouts to be adjusted between each batch to accommodate any component changes the customer may need to make.

Plastic Fabricated Enclosures - Production
Plastic Fabricated Enclosures - Assembly

Case Study

We recently completed a project for an AV company completing an installation at Fulham FC’s Craven Cottage.

They were installing new display boards to for fan updates and advertising. They had specific and restricted space inside the display and after many hours searching for a suitable off the shelf enclosure we found that the only solution was something custom.

They needed an enclosure with enough internal space but also something to fit perfectly within the display boards. The flexibility of the system allowed us to make the enclosure to the exact dimensions and add the important IP66 gasket for the external installation.

Historically an issue like this would have forced redesign for the customer and delay to the project but thanks to the manufacturing speed and flexibility the customer was able to complete the install on time.

Ready to Start?

Connect with our design team to explore tool-free enclosure solutions tailored to your project. Whether you’re planning prototypes or scaling volumes, we streamline the journey from concept to launch.

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