Custom made enclosures services

The development of enclosures made of plastic, metals, and composites. Integration of design ideas with production requirements and product business goals. EnCata designs and creates any part of a product, as well as, enclosures using a plastic enclosure design.

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Designing electronic product enclosures

Engineering services for the development of enclosures made of plastic, metals and composites. Integration of designers' ideas with production requirements and product business goals. EnCata designs and creates any part of a product, even enclosures using plastic enclosure design, that physically separates the exterior from the interior environment of a device. The electroniсal and mechanical part of your prototype is not a finished product without an enclosure. Create your own enclosures starting with enclosure design at EnCata.

Designing the right enclosure is critical for the success of your electronic device, whether it is wireless industrial control, medical equipment, or part of an energy distribution system. The enclosure with all buttons or touchpads is the interface between your buyers and your product functionality. Enclosure design also determines the production cost and durability of your device. Perfect functionality of the electronics and software could be spoiled by poorly designed and produced enclosure.

After the digital design is ready, we will make a prototype using durable and acceptable material for its future environment and use cases. Our customers get a design that meets their needs and also securely keeps hardware components inside. 

We believe that choosing the right material is an important part of the process. If you need a product for sale, we will provide a high-quality enclosure to tolerate a customer's use. If you want to produce a branded product, then we will prepare a design that corresponds to the DNA of your brand. We will design a waterproof enclosure for your product to be able to withstand unfavorable weather conditions. In addition, we will take into account who will use the device. This knowledge leads to the best solution for the product enclosure.

60+ Engineers

We act as your extended R&D team which is faster than hiring engineers locally. The breadth of our technical expertise is unique.

Development Speed

Our dedicated team is ready to scale up quickly. We utilize AGILE lean development process that leads to 30-50% faster delivery.

Burn rate


Our development location enables us to be cost-effective and deliver premium R&D and engineering services at 1/3 of the price compared to that of in N-W Europe and USA.

Custom enclosure design

Our industrial designers start enclosure design  with interviewing the customer to clarify the device functionality and appearance preferences. We prepare a functional description of the enclosure and make some sketches or draft models to discuss the requirements and adjust them with the technology constraints. After clarifying the wishes and specifying the request for enclosure design, we use simulations and modeling, with which we create enclosures with a perfect fit, combining safety, functionality, and cost-effectiveness.

When developing machine enclosure design as well as electronic enclosure design, we look not only at the size and shape of all components but also determine how they will be located and how the end-user will access sensors and a power source.

After the digital design is ready, we will make a prototype using durable and acceptable material for its future environment and the end-user. Prototyping is an important step for designing waterproof enclosures. At this step, we test sealing design.

Industrial Design

Industrial Design gives the maximum opportunity to estimate and think over the interior and exterior of your product. At this stage, easier to adjust and make a decision about the dimensions of the enclosure, as an important part of your final product.

mechanical engineering DFM

Mechanical Engineering

Mechanical Engineering is not only about the development of products that will be mass-produced. Mechanical Engineering includes both Components design and  Enclosure design and development. Starting new projects, we always take into consideration these two parts of customers’ product.

FEA and CFD simulations

Computer Simulations

Numerical modeling is often used at the first stages of product development. When designing the enclosure, it is a big moment to take into account external and internal factors that will subsequently affect the developing device. At CFD stage, we check enclosure ventilation design or gather data to choose material.

Custom electronics design

Electrical Engineering

In our team, we have mechanical and electronics engineers working under one roof. It helps us to consider heat dissipation, antenna arrangement, condensation in the enclosure, convenience of assembly of electronic and mechanical parts, and wiring.

Proof-of-Concept Prototyping

Proof of concept is used not only for the functional tests but also for strength and resistance testing of enclosures. Although as part of the demonstration, we are building a small prototype, a prototype, a mathematical or computer model, which are not necessarily full-fledged products, nevertheless, the body of your device already performs its basic functions.

Moulds and Tools Manufacturing

Metal is the material of choice for many products that need to be durable and cost-effective. With EnCata you can be sure that the shape you've chosen is easily manufacturable. As plastic is much easier to shape with proprietary molds and provides corrosion immunity; we can easily customize it to create unique shapes for your product.

Design an enclosure to go along your product roadmap

At the very beginning, we often dissuade our Clients from developing their own enclosure. It is cheaper and faster to use an adapted standard enclosure. You can place control panel and buttons on it and give it to users. In this case, the main work of the developer is to arrange all the elements inside the standard enclosure and provide auxiliary elements for mounting. 

However, it is necessary to develop your own unique enclosure when your product differentiates from competitors with a new improved design or the main value for the user is ergonomics and design. In this case, it is impossible to test the prototype on users without producing a case that closely follows the shape and texture of the serial product as much as possible. In such projects, we spend a lot of effort both on design and prototyping. We are trying different technologies: 3D printing, silicone molding, vacuum forming. We can even make a manual mold made of aluminum to get the enclosure by injection molding.

Product Development Technology Stack

Research of analogs and solutions in design
Design sketching to explore potential

Concept solutions
Specific human factors and ergonomics knowledge

3D CAD Design & Modelling
3D CAD Modelling for prototyping parts

Reverse engineering
Mechanical simulations 

Engineering calculations

Custom electronics design

Heat exchange simulations 
Waves and signals simulations 


Molding in silicone forms
Finishing and painting

2D drawings and engineering documentation

Engagement Models

We focus on the entire product/service lifecycle, from concept to implementation to market launch.  EnCata’s knowledge, resources and innovation development expertise allow our Clients to develop and expand their businesses faster and leaner.

Some hardware Projects we delivered

Work that highlights the incredible technologies, solutions, and products EnCata developed.

Industries We serve

Our hardware engineers are focus on the entire product/service lifecycle, from concept to implementation to market launch.  EnCata’s knowledge, resources and innovation development expertise allow our Clients to develop and expand their businesses faster and leaner.

FAQ related to Product development

At EnCata, what kinds of contracts do you use? Is it a fixed-term or an agile contract?

EnCata works with both fixed term and agile contracts.

What should I do now that I've approached you with my project idea?

1. Once you have approached us with the project, we conclude the NDA and send the information to the Sales Manager for further evaluation and project planning.
2. The Sales Manager or Sales Engineer will contact you to clarify your goals, requirements and tasks to accomplish. This process is very close to business analysis. When the details are agreed with you, a cost estimate and a quotation are prepared.
3. If you accept the quotation, we will prepare a Technical design specification to document scope of work and requirements and conclude an agreement.
4. After we've signed the agreements, we'll assign you a Project Manager who will gather a project team and report on the project progress.

Can you provide me with a certification of competence?

EnCata employs around 30 engineers with Master's and PhD degrees in electrical and industrial design, mechanical engineering, prototyping and manufacturing from European universities. Each employee is an expert in his or her field.

What level of training do your specialists have?

The majority of specialists are of middle or senior levels. Their range of influence is broad enough to encompass the entire new product lifecycle. Our specialists resolve legal and certification difficulties during the concept stage, optimize production costs during the 3D model development process and create necessary documentation for firmware support. Juniors make up only 15% of the team. They constantly upgrade their qualifications under the supervision of seniors.

Is it possible for us to cooperate with EnCata’s team?

EnCata is always willing to work with its client. We have everything we need to create a collaborative site. Both parties can work on the project simultaneously. The Customer, for instance, and his/ her team designs the electronics while we work on the enclosure. When teams work together to achieve a fantastic result, it is always a win scenario.

Is it possible to discuss the project with your technical team?

EnCata’s team is always willing to discuss all the necessary details about the project proposed. Our full-fledged team of professionals will interrogate you until both parties are satisfied with the procedures necessary to complete the job.

Can EnCata facilitate mass production?

It certainly can. For any product, EnCata creates a design documentation package and a process documentation package that is suited to the production. It should be noted, however, that the technologists at the customer's chosen plant may make changes or impose their own requirements on the documentation design. EnCata, in turn, makes it easier for the client and the technologist to communicate. EnCata does not mass produce, although it can undertake small-scale production at the request of customers.

Do you sign NDAs?

Yes. As a highly professional design and engineering firm, we make sure that all discussions with our clients and all information regarding your invention, idea and other proprietary information are kept confidential.

Patent or Develop first?

We follow a LEAN approach in product and business development and thus we strongly recommend patent filings only after you are  at least part-way through development. This is because patenting is expensive and early patents can already become obsolete or irrelevant later in the development phase. Typically, EnCata's work generates many patentable opportunities for our clients  and the best strategy is to file patents at TRL-7, i.e. when early beta prototype is ready and when a startup is ready to start batch production and marketing.There is, however, another strategy, which is to use provisional patents which can be loose and are not to be disclosed to the public for 18 months. These are much less expensive and time consuming, generally costing below $500.

EnCata will always sign a Non-Disclosure Agreement and keep your intellectual property confidential during the development phase and then we can recommend several third-party patent attorneys when the time is right.

Does EnCata outsource electronics services?

Our in-house professionals handle almost all electronics work, including interface design, protocol development, communication design, schematic design, PCB Design, Firmware design and battery management. If the Customer requires a service that Encata does not supply, we have partners that can meet that need.

Do you write program code, either software or firmware?

We certainly do. EnCata employs electronics specialists who deal with low-level firmware. We also have experts on staff who can implement high-level software code.

Are there hardware engineers in your team?

EnCata employs 12 mechanical and industrial designers and 10 electrical engineers with experience in hardware and firmware. Our team consists of middle and senior level engineers, who have 5+ years of field expertise and have already completed more than 300 projects.

Can EnCata help me with fundraising?

We do indeed help with fundraising through our large business network. However, we typically recommend startups to our partner VCs after we have done some work for the startup and learned more about the team and their core technology. This feedback and recommendation is of great value to all of the friendly VCs as it saves them much time and effort for due diligence.

Have a project to do? Reach out to EnCata team

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