Throughout the commercialization process of EHT's products, I have designed enclosures from scratch for passive components (line drivers, etc) as well as large rack-mount units. I've gained experience in many aspects of enclosure design and productization, including those described below. An essential aspect of this process has been CAD modeling of entire systems, both with SolidWorks and Front Panel Express' proprietary software, FPE Designer. Samples of my work, from most to least recent, can be seen at right. Below are examples are considerations involved in enclosure design.
Air Flow Management & Cooling
Design and Modeling of custom cooling fins/pins, fans, baffles. Arrangement of vents and internal components for optimized cooling of high-power electronic components.
High-Voltage clearances and Capacitive Coupling
Ensuring proper clearances between internal components, both to prevent arcing and reduce performance degradation due to internal capacitive effects.
Shielding of sensitive control hardware and components from high-frequency and high current regions through the use of caging, plating, and general enclosure style to attenuate the relevant wavelengths.
Ease of Assembly
Avoiding overly-complex assembly procedures through the design and use of interlocking parts. Ensuring precision alignment is built into the system, rather than required for assembly.
Hardware User Interface
Optimization of front-panel user experience, including interfacing with external control hardware.
Rack-Mount and Stand Alone Units
Units may be developed with rack-mount wings, feet, or hybrid systems allowing for either mode of installation
Design of functional enclosures around a pre-existing technology, as well as further optimization of pre-existing system for completely integrated final commercialized product.