Mechanical Design Services Enclosures, DFx, and Structural Analysis

Qmax Systems provides mechanical design services - DFx engineering and full structural analysis - from injection-molded plastic enclosures to MIL-grade rugged systems, with a clear path from concept to production.

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Our Core Engineering Capabilities

Qmax Systems delivers precision mechanical engineering across seven specialist disciplines - from injection-molded plastic enclosures for consumer IoT products to MIL-STD-810H-qualified rugged systems for defense electronics. Each service is backed by structural FEA analysis, full GD&T drawing sets, and a direct path from concept to qualified production.

Plastic Enclosure Design

Plastic Enclosure Design for Electronics

Plastic enclosures represent the most common housing choice for consumer electronics, industrial handheld devices, and cost-sensitive IoT products. Qmax Systems designs injection-molded plastic enclosures that balance structural integrity, thermal performance, EMI management, and tooling cost - with a clear path from concept to mass production.

PC / ABSUL94-V0Nylon PA66EMI GasketRF Design
Materials We Work With

Thermoplastics

Polycarbonate (PC), ABS, PC-ABS blends. Nylon PA6 / PA66 and glass-filled engineering variants for structural applications.

Specialist Grades

PTFE (Teflon) for chemical or dielectric applications. UV-stabilised, flame-retardant UL94-V0 compliant materials.

Design Considerations
Draft angles, parting line placement, wall thickness uniformity
Rib & boss geometry, snap-fit and living hinge design
Insert molding for threaded interfaces, EMI gasket seating
RF-transparent dielectric analysis for Wi-Fi, 4G, GPS products
Portfolio
Wi-Fi Security Device Enclosure

IoT / Security

Wi-Fi Security Device Enclosure

Low tooling cost, integrated EMI suppression geometry, antenna keep-out zones for maximum Wi-Fi throughput.

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Case study

Handheld OBD2 Diagnostic Device

Automotive

Handheld OBD2 Diagnostic Device

4G, Wi-Fi, LCD, battery. Workshop-grade drop resistance, ergonomic grip geometry, internal RF coordination.

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Case study

Metal Enclosures

Machined Aluminum, Sheet Metal & Extruded Enclosures

Metal enclosures are the correct engineering choice when the application demands superior EMI shielding, higher structural rigidity, thermal conductance, or a longer service life under mechanical or environmental stress. Qmax designs and sources all three principal metal enclosure types.

Al 6061-T6SS 304/316AnodizingGold Plating
Enclosure Types
TypeTypical ApplicationKey Advantage
CNC Machined AluminumRF modules, high-precision chassis, defense sub-systemsTight tolerances, complex geometry, excellent EMI shielding
Sheet Metal (SPCC, SS, Al)Industrial electronics, rack-mount chassis, control panelsCost-effective for mid-volume, good structural-to-weight ratio
Aluminum ExtrusionHeat-dissipating enclosures, DIN rail housingsIntegral heat sink geometry, excellent thermal path, low per-unit cost
Materials & Surface Treatments

Materials

Al Alloy 6061-T6, 5052; Stainless Steel 304 / 316; SPCC mild steel

Core Treatments

Anodizing Type II / III; Chromate conversion; Powder coating

Precision Plating

Gold plating; Electroless nickel; Hard chrome for wear-critical interfaces

Surface treatment selection is driven by corrosion environment, contact resistance requirements, cosmetic specification, and applicable MIL-SPEC surface treatment standards.

Portfolio
RF Signal Generator Enclosure

Test & Measurement

RF Signal Generator Enclosure

Robust sheet metal enclosure for an RF signal generator platform. Heavy-duty construction provides EMI shielding and structural rigidity, with ventilated panels for sustained operation.

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Case study

TRNDX Server

Industrial Server

TRNDX Server

Mechanically engineered server platform for high-density hardware integration, efficient thermal management, and reliable industrial deployment.

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Case study

Military Rugged Enclosures

Rugged Metal Enclosures for Military Applications - MIL-STD-810 / JSS 55555

Military and defense electronics operate in environments placing extreme demands on mechanical structures: wide temperature cycling, humidity, fungus exposure, sand and dust ingress, shock from weapons fire, vibration from vehicles and helicopters, and altitude. Qmax Systems designs rugged enclosures to MIL-STD-810H (US military environmental engineering standard) and JSS 55555 (Indian DRDO/DGQA equivalent), with full documentation supporting test qualification. Structural analysis is performed before hardware is built, reducing prototype-test cycles.

MIL-STD-810HJSS 55555DRDO/DGQAFEA Pre-qual
Design Approach for MIL-Grade Enclosures
Aluminum alloy castings and extruded / machined Al chassis
Conformal sealed interfaces; EMI gasket seating (finger stock, wire mesh)
Captive fastener systems; shock and vibration isolation mounts
Thermal management integration; MIL-connector cutouts to specification
Portfolio
Rugged Communication Control System Enclosure

Defense

Rugged Communication Control System Enclosure

Ultra-lightweight Al-alloy enclosure for defense communication systems. MIL-STD-810 qualified for vibration, shock, temperature, and humidity with full RF shielding integrity.

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Case study

Industrial Camera Controller Unit

Industrial Automation

Industrial Camera Controller Unit

Compact docking station designed for secure device placement, efficient cable management, and reliable everyday usage in industrial environments.

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Case study

IP-Rated Enclosures

IP-Rated Enclosures - IP65 / IP67 / IP68

Ingress protection ratings under IEC 60529 govern resistance to solid particulates (first digit) and liquid ingress (second digit). Achieving a given IP rating is a mechanical engineering problem. It requires correct selection and compression of sealing elements, proper surface flatness and roughness at sealing interfaces, appropriate fastener torque specifications, cable entry gland selection, and connector IP rating matching.

IP65IP67IP68IEC 60529Viton / EPDM
Ingress Protection Levels
IP65

Dust-tight · Water jets from any direction
Outdoor industrial, field instruments

IP67

Dust-tight · Immersion 1 m / 30 min
Handheld devices, marine equipment

IP68

Dust-tight
Continuous immersion

Seal Design & Validation

Gasket Engineering

O-ring cross-section, durometer, and groove geometry per standard engineering practice. Silicone, EPDM, Viton selected by temperature range, chemical exposure, and compression set.

Test Validation

All IP-rated designs validated at the nearest accredited test facility before production release. Fastener torque fully specified and documented.

Portfolio
4-Axis Gimbal

Marine / Satcom

4-Axis Gimbal

Precision-engineered 4-axis gimbal system designed for smooth stabilization, dynamic balancing, and high-performance motion control applications.

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Case study

EMF Flow Meter

Outdoor IoT

EMF Flow Meter

Compact multi-sensor enclosure with tool-free battery access, integrated antenna mounting, and desiccant cartridge support for extended outdoor deployment.

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Case study

Full Mechanical Systems

Full Mechanical Systems Design

Beyond enclosures, Qmax Systems undertakes complete mechanical system design for products that include moving parts, mechanisms, electromechanical actuation, or complex multi-body assemblies. Our capability spans kinematic design and mechanism analysis through detailed part design, assembly drawing sets, and BOM for procurement.

KinematicsActuatorsOpticalMedical
System-Level Capabilities

Mechanism Design & Kinematics

Linkage geometry, cam and follower, pivot and hinge design, travel limits, actuation force analysis.

Electromechanical Integration

Motor and actuator mounting, encoder alignment, harness routing within mechanical sub-systems.

Optical & Sensor Systems

Mechanical design of optical assemblies and precision mounting structures for demanding environments.

Cable Management

EMI-segregated routing, strain relief design, bend radius compliance throughout the assembly.

Portfolio
Footswitch

Medical Systems

Footswitch

Mechanically robust industrial footswitch designed for reliable hands-free control in demanding operational environments.

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Case study

600Kg Cable Tension Measurement System

Industrial Systems

600Kg Cable Tension Measurement System

Rugged tension meter designed for precise industrial force measurement with durable construction and reliable field performance.

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Case study

DFx Engineering & Compliance

MT, Cost, Assembly & Compliance

A mechanical design that cannot be manufactured repeatably and economically is not a finished design. Qmax applies DFx disciplines throughout the design process - as concurrent engineering that shapes every design decision from the earliest concept phase.

ISO 286ASME Y14.5GD&TRoHS / REACH
DFx Disciplines
DFx DisciplineWhat We Address
DFM - ManufacturabilityTolerances set to process capability. Features designed to the manufacturing method. Tooling complexity minimized.
DFC - CostMaterial selection, process route, finish specification, and fastener standardisation evaluated for BOM cost.
DFA - AssemblyPart count minimization, self-locating features, fastener access, tooling access, and assembly sequence reviewed.
DFC - ComplianceRoHS, REACH, CE marking, MIL, JSS, IEC, ISO addressed at design stage, not at submission.
Documentation Standard

ISO 286

Limits and fits. All tolerances based on functional requirements and the manufacturing process.

ASME Y14.5

Full GD&T-annotated drawing sets. Any qualified machine shop can manufacture without verbal clarification.

Package Contents

Part drawings, assembly drawings, BOM, material callouts, surface finish callouts, and standard references.

Portfolio
Pneumatic Test Jig

Test Equipment

Pneumatic Test Jig

Pneumatic test fixture with precision alignment geometry and DFM-reviewed design for repeatable production testing and assembly validation.

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Case study

Industrial Splice Detector

Industrial

Industrial Splice Detector

Ruggedised industrial splice detector enclosure with extruded aluminum heatsink body, M12 connectors, and DFM-reviewed geometry for factory floor deployment.

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Case study

Thermal & Structural Analysis

Vibration / Impact / Drop / Thermal CFD

Structural and thermal failures in electronics products are almost always predictable - if the analysis is done. Qmax performs FEA-based structural analysis and CFD-informed thermal analysis to identify and eliminate failure modes before hardware is fabricated.

FEACFDMIL-STD-810DO-160IEC 60068
Thermal Analysis & CFD
Junction-to-ambient thermal resistance modeling
Hotspot identification and heat sink geometry optimisation
Thermal interface material (TIM) selection
Thermal derating validation and vent sizing
Structural & Dynamic Analysis
Analysis TypeStatic Stress
StandardFEA linear / non-linear
Expected OutputSafety factors, stress concentrations, deflection maps
Analysis TypeModal Analysis
StandardFEA eigenvalue extraction
Expected OutputNatural frequencies, mode shapes, resonance risk
Analysis TypeVibration (Sinusoidal)
StandardMIL-STD-810 / DO-160
Expected OutputStress response, fatigue life estimate
Analysis TypeVibration (Random)
StandardMIL-STD-810 / JSS 55555
Expected OutputRMS stress, component reliability prediction
Analysis TypeMechanical Shock
StandardMIL-STD-810 Method 516.8
Expected OutputPeak response, component survivability
Analysis TypeDrop Test
StandardIEC 60068-2-31
Expected OutputImpact force, energy absorption, failure prediction
Portfolio
Mega Watt Charging Station

EV / Power

Mega Watt Charging Station

Precision-engineered mechanical assembly system designed for structural stability, modular integration, and manufacturing efficiency.

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Case study

ECL Fuel Cell Generator

Energy Systems

ECL Fuel Cell Generator

Mechanically engineered power system platform designed for efficient thermal management, modular integration, and reliable industrial operation.

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Case study

Why Choose Qmax Systems

We maintain active working relationships with sheet metal fabricators, CNC machining houses, and plastic injection molding companies across India, Europe, and Southeast Asia. Whether you require prototype or volume production - we select the right manufacturing partner based on material, tolerance, finish, lead time, and cost, drawing on over three decades of vendor qualification experience. All mechanical design work is fully documented with clear, unambiguous GD&T (Geometric Dimensioning and Tolerancing) on every drawing, ensuring any qualified vendor can manufacture to specification without further interpretation. We have designed products for the world's top automotive and medical electronics OEMs, and the same documentation rigour applies regardless of project scale.

Case Studies

More Case Studies
Industrial Splice Detector

Industrial Splice Detector

View Case
OTT Media Gateway

OTT Media Gateway

View Case
RF Signal Generator Enclosure

RF Signal Generator Enclosure

View Case
Pulse Oximeter Enclosure

Pulse Oximeter Enclosure

View Case

Frequently Asked Questions

What mechanical design software does Qmax Systems use?
We use industry-standard CAD platforms including SOLIDWORKS, Creo Parametric, and Autodesk Inventor for 3D mechanical design. All structural and thermal analysis is performed using ANSYS and SolidWorks Simulation. Drawings are issued per ISO 286 / ASME Y14.5 GD&T standards and are manufacture-ready without verbal clarification.
Can Qmax manage both the mechanical design and production sourcing?
Yes. Qmax provides end-to-end mechanical engineering - from concept and CAD through drawing release, vendor qualification, prototype oversight, and production ramp. We work directly with your approved manufacturer list or introduce qualified vendors from our network, coordinating DFM reviews, first-article inspection, and tolerance verification.
How does Qmax approach MIL-STD-810 mechanical qualification?
We perform FEA structural analysis - static stress, random vibration, shock, and thermal - before any hardware is built, using MIL-STD-810H test profiles as the loading boundary. This pre-qualification step identifies failure modes early, reduces prototype-test cycles, and produces the documentation trail required for DRDO/DGQA and US military qualification submissions.
What is the difference between IP65, IP67, and IP68, and how do you ensure compliance?
IP65 provides dust-tight protection and resistance to low-pressure water jets. IP67 adds 1 m immersion for 30 minutes. IP68 covers continuous immersion at specified depth. Compliance is an engineering discipline: we specify the correct O-ring cross-section, groove geometry, gasket material (silicone, EPDM, Viton), fastener torque, and surface flatness - then validate at an accredited test facility before production release.
Does Qmax provide GD&T drawings suitable for direct issue to vendors?
Yes. Every design released from Qmax carries a fully dimensioned, GD&T-annotated drawing set prepared to ISO 286 / ASME Y14.5 standards. Tolerances are set based on functional requirements and the manufacturing process - not copied from default CAD settings. Any competent machine shop or toolmaker can manufacture from our drawings without verbal clarification.
How does Qmax integrate mechanical and electronics design to avoid late-stage conflicts?
Our mechanical engineers work in concurrent collaboration with PCB layout and firmware teams from the first concept review. Connector keepout zones, thermal vent placement, board mounting datum, and harness routing are all resolved in CAD before layout begins - eliminating the late-stage ECOs that cause the most expensive product delays.
What is the typical timeline from mechanical concept to qualified prototype?
Timeline depends on complexity. A simple plastic enclosure: 4–6 weeks concept to first article. A sheet-metal rack chassis: 6–8 weeks. A MIL-STD-810H qualified rugged aluminum enclosure: 12–18 weeks including FEA pre-qualification and first-article test. We provide a phased schedule at project kick-off with clear gate reviews and drawing release milestones.