FreeCAD Automotive PCB Enclosure

I have an automotive-grade PCB ready and need a complete enclosure designed in FreeCAD. The enclosure must be easy to manufacture, simple to assemble, cost-effective, and still look professional on the dashboard.

Material preference
My target material is aluminium, so please work to the tolerances, wall-thicknesses, and fastening strategies that suit common aluminium milling or die-casting processes.

What I expect you to do
• Review the hardware design documents for every chip and connector on the board before you start modelling – clearances for all output ports and visibility for the on-board status LEDs are mandatory.
• Ensure the LEDs on the PCB are visible.
• Produce a fully-parametric FreeCAD model with separate bodies for base, lid, seals or gaskets, standoffs, and any fastening hardware.
• Provide exploded and section views that demonstrate ease of assembly and verify tool access for manufacturing.
• Recommend at least one realistic manufacturing route (for example, CNC machining vs. low-volume die-cast) with pros, cons, indicative lead times, and any DFM tweaks you advise.
• Deliver the FreeCAD model, STEP and STL exports plus a concise build note set that a job-shop can quote from immediately. Also deliver documentation of design choices (e.g., why is this part design that way?)

Timing and collaboration
I’m available for quick video calls to speed up decisions and will share the current PCB 3D model the moment we start.

Acceptance criteria
The enclosure must:
– Mount the PCB securely with no component clashes.
– Expose all connectors through properly sized, tool-friendly openings.
– Leave every status LED visible through windows or light-pipes.
– Be manufacturable in aluminium with no undercuts that require complex tooling, unless clearly justified.

After your design is finished, I will test and review it. Once it works, the job is done.