◆ Prototype → Product

A working prototype is not a product yet

The electronics are the hard part, and you have already solved them. What is missing is the housing: the thing a customer picks up, and the thing a manufacturer can actually build. That is what I design.

Prototype Architecture Enclosure DFM Production
# focus dock / passive cooling
load 6.5 W   peak 40.7 °C
rise ~20 °C over ambient
draft analysis 0 undercuts
Validated by CFD, not estimatedFIG. 01
Focus Dock 3-in-1 wireless charging stand, transparent shell showing coils and PCB
SolidWorksKeyShotBlender Injection mouldingSheet metal CFD thermalSTEP / STL / PDF

01 — The work

What the difference actually looks like.

Focus Dock, a 3-in-1 wireless charging stand. Every decision below is one a prototype does not have to make and a product does.

Decisions a prototype never has to make

A second dock position that hides the phone screen instead of showing it. Wood-grain mold finish on the structural spine against matte black on every contact surface, so the material change tells you where to put things. Vent channels sized from measured heat rather than drawn for looks. None of it is necessary to make the thing work. All of it is what separates a product from a prototype that happens to function.

Focus Dock in focus-mode position with phone docked
THERMAL_VALIDATION CFD
Peak40.7°
Over ambient~20°
Dissipated load6.5 W
Phone coil3.0 W
Watch + earbuds1.25 W ea.
PCB regulators1.5 W
Undercut faces0
Vents placed from these numbers rather than estimated. Stated as rise above ambient, which is the only honest way to state it.

Five parts, built to be assembled

One structural body, thin surface covers per contact area, and coil sub-assemblies that install without disturbing the rest of the housing.

Focus Dock exploded view showing five-part construction, coils, PCB and fasteners

The catch that paid for the whole review

The USB-C input fouled the phone in the focus-mode position. Found during review, moved to the rear. Cheap to change on a model. Expensive once the mold is cut. Draft analysis then came back with zero undercut faces, so it releases from a standard two-plate tool.

Focus Dock cutaway view showing internal component layout

Read the full case study

Four colourways, exploded view, x-ray cutaway, compliance label and the thermal work, published on Contra.

Open case study

02 — Pricing

Published prices. No quote required.

Fixed scope, fixed timeline, fixed price. You know what it costs before you write to me.

 

Concept Architecture

For a board that needs a form and a direction before anything else.

$750
10 days · 2 revisions
  • Component and PCB analysis
  • Two form factor directions
  • Layout rationale
  • Material and process recommendation
  • 3 renders
Start this package
◆ Most projects land here

Enclosure Design

For a product going to a manufacturer, where the housing has to actually work.

$1,500
14 days · 2 revisions
  • Everything in Concept Architecture
  • Full SolidWorks enclosure
  • Mechanical integration and fit
  • STEP, STL and native source
  • 6 renders
Start this package
 

Enclosure + DFM

For quoting and producing. The package a manufacturer can price from.

$2,500
21 days · 3 revisions
  • Everything in Enclosure Design
  • DFM review and draft analysis
  • 5 technical drawings
  • Assembly and exploded views
  • Mechanical BOM
Start this package
Add-ons — priced up front, so a change of direction is a decision rather than a negotiation
Additional revision$150
Extra form factor direction$400
Additional drawing$150
Additional render$75
Native source files$250

03 — See the work before you buy it

Two real deliverables, free to download.

Sanitised versions of documents I actually send clients, using Focus Dock as the worked example. Read them and judge the work before you spend anything.

Sample time & cost estimate

How a project gets broken into phases, what each one costs, and what the total looks like before anyone commits.

Download PDF

Sample DFM review

What a design for manufacturing review actually says: wall thickness, draft, tolerancing, part count, and what to change before tooling.

Download PDF

04 — Scope

What I do, and what I hand off.

The second list is the more useful one. It is why the first list is reliable.

I do this

  • Product architecture. How the board, battery, display and connectors occupy a volume that can be built.
  • Enclosure design. Mechanical CAD, fits, tolerances, fasteners, seals.
  • Design for manufacturing. Wall thickness, draft, tolerancing, part count, assembly sequence.
  • Production drawings. The documents a manufacturer quotes and builds from.
  • Manufacturer coordination. Writing the spec they work to, and staying the single point of contact.

I hand this off

  • Mold and tooling engineering. Cavity and core design goes to a specialist. I coordinate it. I do not engineer tooling myself.
  • PCB layout, circuit design, firmware. Your engineers keep the board. I design around what they build.
  • Overseas manufacturer sourcing. I evaluate options and write specs that can be quoted. Vetting factories abroad is somebody else's job.

05 — Who you work with

Eugenio Cruz Cornejo

Electronic Enclosure Consultant · Design for Manufacturing

I help startups and hardware companies turn working electronics into manufacturable products. My work covers enclosure design, product architecture, mechanical integration and hardware concept development, across consumer electronics, battery systems, IoT devices and outdoor equipment. Your engineers keep the board. I make sure what goes around it can actually be produced.

Industrial Design · MBA · MSc Project Management · Tucumán, Argentina

These reviews say almost nothing about enclosures, and that is deliberate. The case study argues the technical side. These answer a different question: whether you will hear back.

★★★★★
“Eugene was amazing to work with, quick to respond and a great listener. He went above and beyond on this project. Highly recommend, would 100% hire him again!”
Susan DriedgerQuality Suze LLC · Upwork
★★★★★
“Eugenio is without question the most experienced, skilled as well as dependable designer I have ever worked with.”
Barry GriffinAzimuth · Contra
★★★★★
“Working with Eugenio was a very positive experience. Def recommend him. Thanks.”
JulianOutdoor audio recorder · Upwork

100% Job Success on Upwork  ·  13 completed projects  ·  10+ years as an industrial designer

06 — FAQ

Questions people ask before hiring me.

Who actually does the work?

I do. There is no studio behind this and nothing is outsourced. You work with the person doing the CAD, which is why the scope boundaries above are drawn honestly rather than sold as capabilities.

My board is not finished yet. Should I wait?

Ideally the board is frozen before the enclosure is built, because a change to the board changes the housing. If it is not frozen, Concept Architecture is still useful, and the later stages are re-quoted if the board moves.

What do you need from me to start?

The board or its mechanical drawing, the components that have to fit, your production volume and process if you know it, and a target timeline. The delivery clock starts when I have that and your files, not at purchase.

Can you take this all the way to production?

I take it to the point where a manufacturer can quote and build, and I stay involved through that conversation. What I do not do is engineer the tooling, for the reasons above.

How do revisions work?

Each package includes a named number of revision rounds. Beyond that, revisions are $150 and a genuinely different form factor direction is $400. Scope changes are quoted before they happen, never absorbed and billed later.

◆ Taking projects

Show me what you have built.

Send a photo of the prototype. Thirty minutes, and you will leave knowing what it costs to turn it into a product and how long that takes, whether or not you hire me.

Email Buy a package
Paid consultations are $75 for 30 minutes and $150 for 60 minutes, credited against a package if you go ahead.