Refined Enclosure Design for Prototype Device

We are building a proof‑of‑concept, voice‑only device for elderly care. The electronics (PCB) and firmware are being handled by a separate engineer and a factory in China. We already have an initial STL / visual concept of the cylindrical device. Your job is to refine this into a manufacturable enclosure: add internal features, mounting points, proper cut‑outs and tolerances, and provide final STEP/STL plus assembly drawings.

Responsibilities
Own the enclosure and mechanical integration of:
PCB (designed by another engineer)
Speaker and microphone
Buttons, LEDs, small display and power connector(s)
Provide early mechanical constraints to the PCB engineer:
Overall enclosure volume and shape
Draft PCB outline and mounting hole locations
Proposed connector locations and openings
Refine the enclosure once the PCB outline and connector locations are confirmed.

You will work with our selected factory/prototyping partner (by email/online) to resolve any mechanical fit or manufacturability issues. We will stay in the loop, but you must be available to answer their questions and update CAD/STL files when needed.

Support basic troubleshooting if physical parts don’t fit as expected (adjust clearances, bosses, openings, etc.).

Inputs We Provide
Existing STL file / visual concept of the cylindrical device.
Industrial design intent / sketches and reference products for the look and feel.
Usage constraints (e.g. table‑top device, viewing angle, cable routing, cleaning/sanitisation needs).
Approximate PCB size and key interfaces (buttons, LEDs, speaker, mic, power).

From the PCB engineer once ready:
PCB outline and mounting hole pattern
Connector locations
Maximum component height above/below the board

Deliverables
Phase 1 – Mechanical constraints (early)
Refined enclosure concept: overall volume and form factor based on the existing STL.
Draft PCB outline and mounting hole locations for the PCB engineer to use.
Proposed connector locations and cut‑outs.
Simple constraints drawing (PDF) and a STEP file of the proposed PCB envelope.

Phase 2 – Enclosure design (refined)
Final 3D CAD model of the enclosure parts (STEP and editable source files).

Internal features:
Standoffs / bosses for PCB mounting
Features to locate speaker, mic, buttons, LEDs and display
Basic cable routing / strain relief
Any simple sealing / overlap features if needed for cleaning.

Phase 3 – Prototype‑ready package
STL files optimised for 3D printing (FDM/SLA) so we can print the prototype housing.
Simple assembly drawing / exploded view (images or PDF) showing:
How PCB, speaker, mic, display, LEDs and power parts fit together
Screw locations, clips, and any fasteners required

Support & Troubleshooting
Be available to:
Adjust mounting bosses, clearances and hole positions if the PCB engineer needs small changes.
Tweak wall thickness or tolerances if printed parts do not fit well on the first attempt.
Review photos/videos from our factory or from us and supply updated CAD/STL files to solve fit issues.
Stay involved until one complete prototype (PCB + enclosure) has been assembled successfully.

Timeline
Week 1: Enclosure concept (based on existing STL) + mechanical constraints package for the PCB engineer.
Weeks 2–3: Refine enclosure based on final PCB outline and connector locations.
Weeks 3–4: Finalise 3D files, support first 3D‑printed prototype.
Week 5: Minor tweaks after real‑world assembly (if needed).

Skills & Experience
Solid experience in mechanical / enclosure design for small electronic products.
Proficiency in 3D CAD tools (e.g. SolidWorks, Fusion 360, Creo, etc.).
Experience designing parts for 3D printing (FDM/SLA) and understanding of tolerances.

Comfortable collaborating with:
An electronics / PCB engineer
A remote factory or prototyping partner
Good communication skills and willingness to iterate based on real‑world test fits.