Custom-made plastic housings for electronics and industrial applications using injection molding

Plastic housings for electronics and HMI applications

Development and manufacturing of custom plastic housings using injection molding

Custom-designed plastic enclosures are far more than just a protective cover for electronics: they influence not only function and ergonomics, but also the degree of integration, assembly effort and design – and thus make a crucial contribution to the long-term economic viability and competitiveness of a product.

We develop and manufacture custom plastic housings.which are not only precisely tailored to your technical requirements, but also to the specific operating conditions and planned production volumes. We accompany your project from the initial design phase through targeted material selection to series production, ensuring that both technical and economic aspects are considered early on and sustainably optimized.

Depending on the requirements, we integrate suitable HMI components Who membrane keypads, silicone keymats or separate silicone protective cases into the housing concept. Also multi-component solutions We implement the functional integration of operating elements, seals or handle zones on a project-specific basis.

The result is Functional, assembly-optimized enclosure solutions with clearly calculable costs, high series production readiness and long-term planning security.

Plastic housings for medical technology and industrial applications

Custom-designed plastic enclosures for electronics and industrial applications

Plastic housing components for technical assemblies

Project examples for custom-designed enclosures

Our work is based on experience gained from various projects in the field of custom plastic enclosures. Applications range from simple enclosures for HMI applications to more complex assembly solutions – each tailored to the technical and economic requirements of our customers.

Robust plastic housings for handheld devices and industrial applications

Compact plastic housings for electronic modules and industrial components

Project references for enclosure projects

Handheld housing with circumferential seal

For a customer in the industrial metrology sector, we developed a custom handheld housing with an integrated circumferential seal. A key feature of this concept is that the seal is not a separate component, but rather an integral part of the housing design.

The seal functionally connects the upper and lower shells, ensuring a defined and reproducible joining situation during assembly. Separate inserts or additional assembly steps are eliminated, significantly increasing process reliability, sealing quality, and efficiency.

The plastic housing was ergonomically designed for mobile use and seamlessly integrates the display and controls into the overall design. The result is a robust, durable, and series-optimized solution with high assembly quality and clearly calculable cost-effectiveness.

Development of a custom plastic housing from sketch to product

3D CAD design of a custom plastic housing

Design of a plastic housing with a focus on design and function

Prototype of a customer-specific plastic housing before series production

Finished custom plastic enclosure for electronic applications

Custom handheld plastic housing in final design

Custom-designed housing with matching silicone protective cover

For a manufacturer of industrial measurement technology, we developed a custom-designed plastic housing with a precisely matched silicone protective cover. The goal was to create a robust, durable, and ergonomically optimized housing concept for mobile use.
The plastic housing was designed to integrate operating elements, interfaces, and internal electronics. Wall thicknesses, screw points, and sealing surfaces were optimized for manufacturing to ensure high series production readiness and stable assembly processes.

The precisely fitting silicone protective case functionally complements the housing and provides targeted protection against impacts, edge stress, and mechanical wear and tear during daily use. At the same time, it improves grip and feel.

The result is an assembly-optimized, economically scalable and system-integrated housing solution with high process reliability and long-term planning perspective.

Custom-designed injection-molded plastic housing for industrial measurement technology

Plastic housing with silicone protective cover for mobile measuring devices

Plastic housing with integrated silicone switching mat as sealing and operating element

For a customer in the building automation sector, we developed a custom plastic housing in which the silicone keypad is structurally integrated into the housing design, serving both as a keypad and a sealing element. The goal was to optimize the housing's functionality, reduce the number of components, and simplify the assembly process.

The silicone switching mat not only performs the defined switching function with precise tactile feedback, but also seals the transition between the upper and lower housing shells. Separate sealing elements are eliminated, thus reducing interfaces and increasing process reliability.

The plastic housing was designed for manufacturing and precisely tailored to the integration of the switching mat. This resulted in a robust, assembly-optimized, and economically scalable series solution with clearly defined functions in an integrated overall concept.

Plastic housing with silicone keypad for industrial operating devices

Ergonomic plastic housing with silicone switching mat for handheld devices

Plastic housing in multi-component injection molding with integrated silicone overmolding

We developed a round [product/service] for a manufacturer in the field of safety and signaling technology. Plastic housing Multi-component injection molding with a directly molded silicone protective structure. The goal was a compact, impact-resistant, and durable plastic housing that constructively combines mechanical protection, lighting function, and haptics in a single component.

The transparent base of the impact-resistant thermoplastic housing was specifically designed for the integration of the LED unit and for circumferential light emission zones. Wall thicknesses, rib geometries, and mounting points were optimized for manufacturing to ensure dimensional accuracy, warpage resistance, and cost-effective series production.

In the second process step, a silicone component was directly injection-molded onto the plastic housing. This provides shock protection, a spacer function, and improved tactile feel simultaneously. The functional overmolding creates a protective contour that absorbs mechanical stresses and significantly increases the plastic housing's durability in daily use.

The result is an assembly-optimized, function-integrated plastic housing with high process reliability and clear scalability – ideal for industrial applications with increased demands on robustness and cost-effectiveness.

Plastic housing in multi-component injection molding with integrated silicone overmolding

Plastic housing with silicone overmolding for protection, sealing and shock absorption

When are custom enclosures the better solution?

Custom plastic housing from CAD design to series production

Standard enclosures are often a pragmatic starting point for early development phases. However, as production readiness increases, clear limitations become apparent: limited integration, compromises in ergonomics and design, and rising unit costs over the product lifecycle.

Custom-designed plastic enclosures offer advantages when:

Functions, electronics or controls are to be integrated
Ergonomics and user acceptance play a role
Design and differentiation are important
medium to large production runs are planned
Long-term availability must be ensured
A defined target price should be achieved and kept stable throughout the project duration.

Even in the early project phase, we work with you to determine whether and from what quantity a custom-designed plastic housing is economically viable. Starting from medium production runs (approx. 1.000 pieces) Despite initial tooling costs, customized solutions can be more economical in the long run than using standard enclosures. The decisive factor is not the unit price at the start of the project, but rather the... Total cost analysis over several years.

Standard enclosure or customized enclosure solution?

When developing new devices, using standard enclosures initially seems like the obvious choice – especially in the early project phases. However, even with medium production runs, it becomes more cost-effective. the investment in a custom-designed enclosure Clearly: Tooling costs are quickly amortized, series production prices fall, the Assembly effort is significantly reduced Additional functions can be integrated directly into the assembly. This creates an economical, functional, and perfectly tailored solution that ensures the long-term success of your product.

Practical example from medical technology:
How switching from a standard solution to a customized enclosure reduces costs, assembly effort and the variety of options.

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Practical example from measurement technology:
From standard enclosures to customized solutions: When the switch makes economic sense.

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Custom plastic enclosures vs. standard enclosures

Comparison based on technical and economic criteria

Criterion	Custom plastic enclosures	Standard housing
Availability & Project Start	Initial development effort, but in return a clearly planned project start, coordinated processes and a safe series production ramp-up.	Available at short notice, ideal for prototypes, pilot projects and early project phases
Investment structure	A one-time tool investment that pays for itself through decreasing unit costs.	No traditional tooling costs, but permanently higher unit prices.
Unit costs & profitability	Decreasing unit costs with increasing quantity; often significantly lower Total Cost of Ownership (TCO)	Economical for small production runs or unclear sales volume
Design & Integration	The case, display, keyboard, cable entry and battery compartment are developed jointly from the very beginning.	Electronics, display and controls must be adapted to the housing.
Protection & Robustness	Mechanical protection, e.g., through precisely fitting silicone protective covers or integrated seals, specifically tailored to the application.	Defined IP protection classes are available; additional protection is often only possible via external components.
Design & Variant Capability	High degree of design freedom; creation of variations through different material colors, engravings, paint finishes, materials, etc.	Design, colors, and geometry are predetermined.
Supply chain & life cycle	Customer-owned tools ensure long-term supply security and stable prices.	Dependence on catalog availability, price changes or product discontinuations
System delivery & purchasing	System delivery from a single source reduces interfaces, coordination effort and administrative costs.	Multiple suppliers, increased coordination and administrative effort

Economic advantages through systems thinking

The cost-effectiveness of custom-designed enclosures is not solely determined by the price of the individual parts, but by considering the entire system:

Reduced number of individual parts
Reduced assembly and integration effort
Simplified logistics
Improved scalability across the product lifecycle
Long-term independence from catalog products and product discontinuations

This is how sustainable cost advantages over several years.

Graphics cost comparison: custom plastic enclosure vs. standard enclosure

Design Guide Plastic Moulded Parts

Our service: Customized – without any extra effort on your part

A custom enclosure solution doesn't have to be a complex or risky project. We support you from the initial concept to series production, handling all technical and organizational coordination.

Even in the early stages of a project, we work with you to determine whether and from what quantity a customized solution is economically viable. Based on your requirements, we develop a manufacturable enclosure concept – including material selection, protection concept, and input systems.

Through our experience in the development and manufacturing of Plastic molded parts,silicone protective cases, membrane keypads and Connection Technology Tailor-made system solutions are created from a single source. This reduces interfaces, minimizes coordination efforts, and ensures fast, reliable industrialization.

For you this means: clear costs, predictable timelines and manageable internal effort – while maintaining a high level of technical and economic reliability. We would be happy to discuss with you whether a custom-designed plastic enclosure makes technical and economic sense for your project.
Based on your requirements, we will create a well-founded assessment – structured, transparent and non-binding.

Our services in the field of plastic housings

As a system supplier, we provide comprehensive support for your project:

Consulting & Concept Development
Analysis of requirements, operating environment and target costs
Construction & Design
Housing design, wall thicknesses, detents, sealing concepts, fastenings
Material selection & surfaces
ABS, PC, PC/ABS, other engineering plastics
Surface textures, colors, lettering
Prototypes & Pre-series
Functional prototype, design validation, assembly testing
Serial Production
Injection molding and 2K injection molding solutions for stable series production processes
Integration of additional components
Displays, membrane keypads, silicone parts, cables, connectors, assemblies

Engineers developing and sampling a plastic molded part for an HMI operating unit

Plastic housing with integrated electronic components and controls

Comprehensive enclosure solutions – from mechanics to connection technology

Plastic housing with integrated HMI components, electronics and connectors as an assembly — Integration of HMI, electronics and connection technology

We continue to develop and manufacture customer-specific molded plastic parts with integrated magnetic connectorsHigh-performance spring contact pins and magnets are integrated directly into the housing design. This results in compact, robust, and intuitively operated connection solutions that are particularly suitable for industrial applications. The associated Kabelkonftion It is also developed and manufactured by us to fit perfectly, resulting in a complete system solution.

magnetic connector

Keyboards

Covers

This is how we start your project

In order to make you an initial offer, we need the following information:

Technical drawing, sketch or an existing sample
If you do not yet have a technical drawing, we will be happy to create one for you.
Short product description with area of application
The more details you give us, the more precisely we can tailor the offer to your requirements.
Optional additional information
If available, please send us a specification sheet, technical specifications or special equipment details.
Planned quantity or estimated annual requirement
This helps us to optimally align production to your requirements.

To protect your data and ideas, we can conclude a non-disclosure agreement (NDA) in advance. If you do not have your own NDA, we will be happy to provide you with our template.

NDA template

We look forward to your inquiry.

+49 (0)2154-81250

info@nh-technology.de

Personal Meeting

A personal conversation is particularly important to us when it comes to getting to know each other for the first time and discussing complex or new projects. We want to ensure that we fully understand your requirements and needs and can provide you with the best possible solution.

Of course we are also available to you via email Online meeting available. We use various platforms and tools to ensure seamless and effective communication.

In our Showroom Porto Cervo you have the opportunity to see for yourself the quality and functionality of our products, to receive individual advice and to try out the different models. Our team of experts is available on site to answer all your questions and to work with you to find the perfect solution for your requirements.

Contact Simply contact us to Appointment to arrange a meeting and get to know each other. We look forward to it!

Technical FAQs on plastic housings – development, design and manufacturing

Our technical FAQs for custom plastic enclosures answer key questions about design, material selection, and manufacturing. We consider both technical requirements and economic aspects such as assembly effort, costs, and availability. This provides you with a solid foundation for your development and procurement decisions.

Do you have any further questions or a specific project? We would be happy to support you in the development and implementation of your plastic enclosures.
Contact us – we will advise you without obligation.

How can a custom-designed plastic enclosure reduce overall costs?

We design enclosures with integrated functions, including fasteners, seals, and guides. This reduces the number of individual parts and assembly steps, minimizing potential errors and rework. For you, this translates to lower assembly costs and more stable series production.

When does a standard enclosure make sense – and when is a customized solution worthwhile?

Standard enclosures are a quick and cost-effective solution, especially for simple requirements or small production runs. However, as soon as specific requirements arise regarding installation space, function, design, or integration, standard solutions quickly reach their limits.
We would be happy to assess whether a customized solution makes economic sense for you. We will compare your current standard solution with a custom enclosure design. Often, long-term cost reductions can be achieved through functional integration, reduced assembly effort, and optimized components.
The assessment is non-binding and focuses clearly on technical feasibility and economic viability. This provides you with a sound basis for making decisions about your project.

How can we support you if a standard enclosure is currently being used?

If you are already using a standard enclosure, we will analyze your existing solution systematically and practically. We will consider installation space, functionality, assembly effort, and necessary modifications such as milling, drilling, or additional mounting brackets. The goal is to identify specific weaknesses and optimization potential.

In the next step, we conduct a comprehensive cost analysis. In addition to the pure cost of the parts, we also consider assembly times, additional components, scrap risks, and logistical costs. Based on this analysis, we demonstrate whether and from what quantity a customized enclosure solution becomes economically viable. We also examine how specific functions can be integrated, such as fastening systems, sealing concepts, or the integration of electronics. This allows for a reduction in the number of components and simplification of assembly processes. In many cases, this results in measurable cost savings throughout the entire product lifecycle.

The analysis is non-binding and based on your specific application. You will receive a sound basis for decision-making that takes both technical and economic aspects into account.

How can we support you in the cost-optimized design of plastic enclosures?

We begin our work in the early development phase, specifically analyzing the cost drivers of your enclosure. These include geometry, material usage, tooling concept, and assembly effort.
We optimize components through consistent wall thicknesses, reduced undercuts, and tool-friendly design. This allows us to avoid complex tooling and lower investment costs. At the same time, we examine which functions can be directly integrated. This reduces the number of individual parts and simplifies assembly.
We also tailor the material selection precisely to the requirements. This allows us to avoid over-dimensioning and unnecessary material costs. Where appropriate, we use multi-component injection molding to directly integrate seals or functional elements. This reduces the number of additional components and assembly steps.
In addition, we consider the entire system. We analyze how design, manufacturing, and assembly can be optimally coordinated. For you, this means lower tooling costs, reduced unit costs, and economical series production.

How does the development of a plastic housing proceed?

We begin by jointly defining the technical requirements and constraints. These include installation space, function, environmental conditions, and economic objectives. Based on this, we develop an initial concept and coordinate design, materials, and manufacturing early on.

We then create the structural design. In doing so, we consider manufacturing aspects such as wall thicknesses, demolding, and tool-compatible geometries. At the same time, we ensure sensible functional integration to reduce component numbers and assembly effort.

In the next step, we create prototypes and validate them under realistic conditions. This allows us to identify potential adjustments early on and implement them effectively. After successful validation, we design the tooling for series production and transition to manufacturing.
This structured process ensures that your plastic housing functions reliably from a technical standpoint and can be implemented economically.

How quickly can a plastic housing go into mass production?

The project duration depends on complexity, component size, and requirements. In practice, the time until series production typically ranges between 8 and 16 weeks.
Simple enclosures with clearly defined requirements can often be implemented more quickly. More complex projects with high demands on design, sealing, or integration require correspondingly more time. A significant factor here is the time required for tooling and sampling.

Our structured development process and early coordination reduce iterations as early as the concept phase. Prototypes enable rapid validation, allowing for early adjustments. This shortens the time to series production and creates a high degree of planning certainty for your project.

How do we integrate electronics and HMI components into the housing?

We develop enclosures as functional units. Circuit boards are securely fixed and operating elements are precisely integrated. These include displays, membrane keypads, and silicone touch mats. At the same time, we consider cable routing, sealing concepts, and EMC requirements. This results in a user-friendly and reliable overall solution.

How do we design the tooling strategy and safeguard your investment?

We tailor the tooling strategy to your individual needs and establish clear parameters from the outset. Together, we clarify aspects such as tool design, application location, and service life. This creates a transparent and predictable foundation for your project.
Through design optimized for manufacturing, we ensure that tools can be used efficiently and operate reliably in the long term. At the same time, we make sure that later modifications or variations remain possible, insofar as this is technically feasible.
For you, this means a secure investment, predictable costs and high flexibility throughout the entire product lifecycle.

How do we ensure the quality and dimensional accuracy of your enclosures?

Together with you, we define all relevant requirements and tolerances. Continuous quality controls are carried out during production. Thanks to our location in Shanghai, we oversee manufacturing directly on-site. In addition, we test components in the N&H laboratory. This ensures consistent functionality, material properties, and dimensional accuracy.

How is delivery capability and security of supply guaranteed?

We ensure our ability to deliver through a qualified international supplier network, which we carefully select and regularly audit. This guarantees stable and reliable manufacturing processes.

With our own location in Shanghai, we directly oversee production on-site. We conduct additional quality controls and can react to any deviations early on. This increases process reliability and reduces response times.

In addition, we coordinate closely with our partners, thereby creating transparency along the entire supply chain. If required, we implement warehousing and call-off concepts, for example with buffer stocks. This allows us to stabilize delivery times and flexibly compensate for fluctuations in demand.

In addition, where appropriate, we utilize alternative supplier structures. This reduces dependencies and increases security of supply. For you, this means predictable delivery times, stable prices, and reliable procurement.

How flexibly can we react to changes during the project?

We coordinate closely with you and respond quickly to adjustments. Changes can be implemented particularly efficiently in the early project phases. At the same time, we place great emphasis on clean development to avoid later adjustments. This way, you keep costs, deadlines, and risks under control.