Problem

Create a compact enclosure for an AC EV charger that presents a premium, minimalist facade while surviving outdoor exposure and enabling fast line assembly.

Approach

• Modular shell: powder-coated aluminium shroud + PC-ABS base.
• Hidden service channel: cable management & strain-relief path.
• Gasket stackup with controlled compression for IP54.
• Datum-led DFM: fewer fasteners, single-tool access, poka-yoke.

Result

• Architectural slat fascia hides fixings and venting lines.
• Assembly steps collapsed from 12 → 8; takt time reduced.
• Ingress & thermal paths validated by test fit and CFD pre-check.
• Documentation pack: BOM, drawings, assembly SOP, QC checks.