Instructables
Picture of Simple Project Enclosure for Circuits
Creating a proper enclosure for an electronics product can be a pain in the neck sometimes.  The box isn't big enough.  Or your buttons and connectors don't fit.  You can't get to the battery after you put it all together.  There is always something.

Well, if you have access to a laser cutter, I've found the following technique quick and painless.

Technically, it is not exactly a full enclosure, just a top and bottom panel attached to each other using standoffs, but it is very versatile and easy to work with.
 
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Step 1: Materials and Tools

Picture of Materials and Tools
standoffs2.jpg
Materials

Acrylic, I used 1/8" thick
Circuit Board, I used this one from Radio Shack
Standoffs, you can find these all over the place, I used McMaster-Carr
Nuts and screws that fit the standoffs, again I used McMaster

Tools

Laser Cutter
Screw driver
Small wrench

You will also need some sort of vector graphics program to create/edit the panels, I used Adobe Illustrator.  Below are the files I used for this project.

Top Panel
Bottom Panel

The most important thing is that your panels have mounting holes in the same position as the circuit board you're using.

I've also found it very helpful to laser etch the name of the circuit into the top panel and the actual circuit diagram on the bottom panel.
iq20111 months ago
That came out really nice! I'm going to try this with a Dremel, bit #561, and a straight edge tool. I saw a guy cut acrylic pretty well with this setup. A laser cutter is not accessible to most hobbyists. A Dremel is.
That looks so awesome!, now to find a laser