Explosion-Safe PCB Enclosure Design
Budget: $250 – $750 USD
I have a compact signal-processing circuit that must operate safely in an explosive-gas environment. What I need is a production-ready multilayer PCB plus a matching 3D-modelled enclosure that can move smoothly through hazardous-area certification.
The PCB will be like this example
https://www.alibaba.com/product-detail/Winsen-ZEHS04-All-in-One-Atmospheric_1600576561791.html?spm=a2700.shop_index.89.1.3bc37808qqYHly
But the cylindrical sensors models will be different from here. This PCB will be mounted on the back of a ESP32.
We have the model selected. The power, BLE & Wi-fi will be selectable from internal or external.
You design component placement, and stack-up while respecting intrinsic-safety spacing and thermal limits. KiCad files with editable schematics, Gerber files needed.
For the housing I expect a rugged, gas-tight design with proper gaskets ,seals, cable glands, and earth points so you can get Ex ia/Ex d approval. Resettable electronic fuses & status LEDs for diagnostics. The 4 sensors will have a filter & opening for exposure to air. The HW shall be included unless you take exclusion. The enclosure will have a grommet incision for cable entry, open up so work can be easily done inside. A manufacturable STEP model ready for 3D print is essential. The enclosure will be mountable on Din rail, human wearable or with a magnet mount. We shall approve your design for acceptance.
You may submit optional proposal for the firmware development with all editable source code, supporting documentation to be provided. An embedded mobile-friendly web server with config, status & operational live data. a audible horn, viberator & LED alarm. 2 DOs for external alarm, warning dry contact. The relevant data exposure via BLE & Wi-fi to host systems using MBTCP server. Include FMEA & MTBF.
Deliverables
• Complete PCB design data (schematic, layout, Gerbers, BOM, pick-and-place)
• 3D enclosure model and assembly drawings
• Short design note showing how the layout and enclosure address explosive-gas requirements
User manuals, stress testing, hazard certification included.
If you’ve already taken hardware through ATEX, IEC Ex, or similar approval, please mention it—real-world hazardous-area experience is key for this project.
Please address the following..
1. You are honest, sincere, have capability, capacity to do this job.
2. You have the drive & hunger for this work & take responsibility for your bid.
3. No upfront
4. No AI or bots to be used for response.
5. Our budget is placeholder only, you bid your best figure with delivery. If you did not specify the fixed price, we shall take it was $400 for all inclusive in 2 weeks (time to design)
6. Submit your questions with response. Any other issues will be addressed after award.
The PCB will be like this example
https://www.alibaba.com/product-detail/Winsen-ZEHS04-All-in-One-Atmospheric_1600576561791.html?spm=a2700.shop_index.89.1.3bc37808qqYHly
But the cylindrical sensors models will be different from here. This PCB will be mounted on the back of a ESP32.
We have the model selected. The power, BLE & Wi-fi will be selectable from internal or external.
You design component placement, and stack-up while respecting intrinsic-safety spacing and thermal limits. KiCad files with editable schematics, Gerber files needed.
For the housing I expect a rugged, gas-tight design with proper gaskets ,seals, cable glands, and earth points so you can get Ex ia/Ex d approval. Resettable electronic fuses & status LEDs for diagnostics. The 4 sensors will have a filter & opening for exposure to air. The HW shall be included unless you take exclusion. The enclosure will have a grommet incision for cable entry, open up so work can be easily done inside. A manufacturable STEP model ready for 3D print is essential. The enclosure will be mountable on Din rail, human wearable or with a magnet mount. We shall approve your design for acceptance.
You may submit optional proposal for the firmware development with all editable source code, supporting documentation to be provided. An embedded mobile-friendly web server with config, status & operational live data. a audible horn, viberator & LED alarm. 2 DOs for external alarm, warning dry contact. The relevant data exposure via BLE & Wi-fi to host systems using MBTCP server. Include FMEA & MTBF.
Deliverables
• Complete PCB design data (schematic, layout, Gerbers, BOM, pick-and-place)
• 3D enclosure model and assembly drawings
• Short design note showing how the layout and enclosure address explosive-gas requirements
User manuals, stress testing, hazard certification included.
If you’ve already taken hardware through ATEX, IEC Ex, or similar approval, please mention it—real-world hazardous-area experience is key for this project.
Please address the following..
1. You are honest, sincere, have capability, capacity to do this job.
2. You have the drive & hunger for this work & take responsibility for your bid.
3. No upfront
4. No AI or bots to be used for response.
5. Our budget is placeholder only, you bid your best figure with delivery. If you did not specify the fixed price, we shall take it was $400 for all inclusive in 2 weeks (time to design)
6. Submit your questions with response. Any other issues will be addressed after award.
Related categories:
Electronics
CAD/CAM
Microcontroller
PCB Layout
Product Design
3D Modelling
Embedded Systems
Signal Processing