Electronic Speaker Housing

Project Name

Electronic Speaker Housing


A new client dissatisfied with the high costs typically found in the injection modeling process

Customer Needs

This customer has shopped around and worked with other companies and is dissatisfied at the high costs associated when using an injection modeling process. They require an electronic enclosure to house their hardware, including a battery pack.

A customer approached Toolless inquiring about an electronic enclosure to house their parts. They knew what they wanted their enclosure to look like and provided us with a 3D model based on an injection molded design. Our goal was to take this 3D model and modify it so that we could manufacture the product using Toolless technology at a lower cost to the customer.

Ongoing Design Process

When our engineers are given a 3D model from a customer they review the specifications and talk to the customer to determine what it is the customer desires. Our engineers then create their own 3D model—one in which takes the original model, keeping to the customer specification and needs, and generates a new 3D model which is compatible to Toolless technology. This is an important first step, because it helps to show customers that we have the capabilities to create their enclosure to their provisions.

The 3D model on the left was created by our engineers and the 3D model on the right is what we were approached with by the customer.

As one can see, changes were made but the overall size, functionality, and purpose of the enclosure remained the same.

Once a 3D model was created, the customer was contacted to discuss the model and to explain the adaptations that were made.

One of the variations that occurred between the two 3D models had to do with the 4 Hex protrusions at the bottom center of the original 3D model. These protrusions were meant to secure the enclosure to another part the customer had, as this enclosure was just one unit of a bigger product. We came up with a simpler solution of using a mounting ring with threaded inserts so that the enclosure could still be secured.

However, at Toolless our engineers are dedicated to ongoing design improvement. After further testing and discussion with the customer, it was decided to change the mounting ring to a tray. This change allowed the enclosure to be secured, as well as making the enclosure more rigid, created additional support for the necessary hardware.

Showing the change to tray in 3D (left) as well as the actual inside of the enclosure (right)


Due to the large size of the housing, it was determined that additional ribbing on the inside of the top part would be beneficial to create a more rigid product. When adding ribbing to an enclosure, we need to determine the proper spacing so that we can create optimal rigidity without interference with the customer’s hardware. This 3D model shows the ribbing that was created on the inside for the top of the enclosure.

For the base we decided to run the ribbing from front to back and added a double plate at the bottom. The purpose of having the ribbing run in a different direct was to allow room for the hardware and still maintain strong rigid enclosure.

Another challenge we tackled was to design a battery box that would fit without increasing the size of the enclosure. There was a lot of flexibility from the customer about the placement of the battery box. To the left is the original placement of the battery box.

There were 3 main things we had to consider when designing the placement.

  1. The battery box needed to be placed where it wouldn’t interfere or come into contact with the support ribbing.
  2. Move the mounts for the battery door from the top and bottom to the sides. This was done so that the threaded inserts and screws did not interfere with ribbing and supports.
  3. We did not want addition hardware interfering with ribbing and supports, so instead of securing the battery box with screws, we used a special glue to solvent weld the battery box to the rear panel.

End Result

Final Design: We successfully took a 3D model for an injection molded design and re-designed the enclosure so that we could produce with no mold, and no tooling. Our customer was satisfied with the product, as it not only met their needs to house their electronics but was more cost effective than using an injection molding process.