Customized Sensor Housing Project for a U.S. Client

Client Background
This product was custom-developed by FCE for a U.S. client specializing in sensors and industrial automation equipment. The client required a quick-release sensor housing to facilitate maintenance and replacement of internal components. Additionally, the product needed to offer excellent sealing performance and weather resistance to adapt to various complex application environments.
Material and Application
The sensor housing is made of polycarbonate (PC) through precision injection molding. PC material offers the following advantages:
High strength and impact resistance, effectively protecting the internal sensor from external damage.
High-temperature resistance and aging resistance, making it suitable for various industrial and outdoor environments.
Dimensional stability, ensuring precise assembly and enhanced sealing performance.
Lightweight design, facilitating installation and maintenance.
This housing is designed to protect electronic sensors from dust, moisture, and mechanical damage, thereby improving equipment reliability and service life. Its quick-release design allows for easy maintenance, making it ideal for applications requiring frequent sensor replacement or internal servicing.
FCE’s Solutions and Technical Breakthroughs
During the project development, FCE helped the client address the following key challenges:

Quick-Release Design

Utilized a snap-fit structure, allowing the housing to be opened quickly without additional tools, significantly improving maintenance efficiency.
Optimized structural design to ensure the disassembly process does not compromise sealing performance or durability.

High Sealing Performance and Weather Resistance

Designed an effective sealing structure to prevent water vapor and dust intrusion, meeting IP protection rating requirements.
Selected weather-resistant PC material to ensure long-term use without deformation or aging.

High-Precision Injection Molding

Since PC material is prone to shrinkage and deformation during the injection process, FCE applied precision mold design and optimized process parameters to ensure dimensional stability.
Employed high-precision molding techniques to enhance component compatibility, ensuring optimal sealing and assembly reliability.
The successful development of this sensor housing not only meets the client's requirements for quick assembly, sealing performance, and durability but also showcases FCE’s expertise in precision injection molding, functional plastic part design, and structural optimization. The client highly recognized the quality and performance of the final product and plans to establish a long-term partnership with FCE to develop more high-performance plastic housing solutions.