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About Project

This project features a compact cylindrical housing designed for a small air-sensor module. With a diameter under 10 cm, the enclosure integrates refined functional features: curved ventilation slots for optimized airflow, precise internal mounting pillars for sensor and fan components, and clean openings for ports or indicator modules. The overall layout focuses on stability, heat dissipation, and reliable alignment of the internal electronics-essential qualities for any environmental-monitoring device.

To prototype this enclosure, we used Flashforge Tough, a filament engineered for applications requiring a balance of strength, impact resistance, and dimensional accuracy. Compared with regular PLA, Flashforge Tough offers higher toughness and less brittleness, making it ideal for functional prototypes that undergo repeated assembly, screw fastening, or long-term use. Its stable shrink performance also ensures tight tolerances for parts like snap-fits, screw bosses, and precision-vented surfaces.

The result is a durable shell capable of withstanding everyday handling while protecting sensitive sensing components. Its matte black finish and consistent layer pattern further enhance the professional appearance of the prototype-critical for client demonstrations and field testing.

Where Flashforge Tough Performs Well:

• Electronic housings and IoT device shells
• Structural prototypes requiring impact strength
• Small appliances, sensor modules, and wearable-tech casings
• Fixtures, jigs, and mechanical parts needing reliable toughness

At FacFox, projects like this highlight the value of rapid, reliable additive manufacturing for product development. Whether you’re refining a concept, validating assembly mechanisms, or preparing for investor demos, our team can help you turn ideas into functional prototypes with speed and precision. We support a wide range of materials-including engineering filaments, resins, and industrial-grade polymers-to match your performance requirements.

If you’re developing an electronic enclosure, sensor product, or any small device that demands both durability and clean aesthetics, FacFox’s professional 3D printing service can accelerate your workflow and deliver production-ready results.

Solution

• Step 1: 3D Model Design. The air-sensor module housing was designed in CAD software. All ventilation slots, mounting pillars, and openings were modeled to match the client’s internal components.
• Step 2: File Preparation. The finalized 3D model was exported as an STL file. The file was checked and any minor mesh errors were repaired to ensure watertight geometry.
• Step 3: Slicing Setup. The STL file was imported into slicing software. Layer height, infill density, print speed, and support settings were configured according to the requirements of Flashforge Tough material and the desired surface quality.
• Step 4: Printer Preparation. The FDM 3D printer was calibrated. The build plate was leveled, the nozzle was cleaned, and Flashforge Tough filament was loaded into the extruder.
• Step 5: Printing Process. The sliced file was sent to the printer. The housing was printed layer by layer, and the curved ventilation pattern and internal structures were gradually formed.
• Step 6: Support Removal. After cooling, the printed part was removed from the build plate. All support structures around the ventilation slots and internal pillars were carefully removed.
• Step 7: Surface Finishing.The housing was lightly sanded and any minor imperfections were smoothed. Edges around openings and screw bosses were deburred to ensure safe handling and easy assembly.
• Step 8: Dimensional Inspection. Key dimensions such as the outer diameter, wall thickness, and mounting hole positions were measured. The part was verified to fit the sensor module and associated hardware.