Prototype Electronic Devices with 3D Printing: A How-To Guide

3D Printing Tips & TricksManufacturing Innovation
Written By Dan Kreisher

Prototyping electronic devices has never been easier thanks to the power of 3D printing. With tools like Autodesk Fusion 360 for designing custom enclosures and the ability to iterate quickly, you can bring your ideas to life faster than ever. In this guide, we’ll dive into designing, material selection, and assembly to help you create the perfect prototype.

1. Designing Your Enclosure

Electronic Enclosure designed using Autodesk Fusion 360

The first step is creating a design that fits your electronic components snugly. Our go-to design software, Autodesk Fusion 360, makes this process seamless with its intuitive interface and powerful 3D modeling tools. While designing, be sure to account for the necessary ports, buttons, and ventilation for your device. Don’t forget to plan for internal space to accommodate circuit boards and batteries—you want everything to fit perfectly, not a single wire out of place!

2. Selecting the Right Material

When it comes to material selection, durability and heat resistance are key. We love using engineering resins for their strength, tough resins for functional prototypes, and clear resins when we need transparency for indicators or displays. Each material offers unique benefits, so choose based on your device’s specific needs. Whether you’re going for flexibility, impact resistance, or clarity, there’s a resin that’s perfect for the job.

3. Mounting and Assembly

One of the best things about 3D printing is the ability to integrate mounting points directly into your design. For attaching circuit boards and other components, we’re big fans of using knurled threaded inserts—they provide a strong, reliable grip and make assembly a breeze. You can also design snap-fit features for quick assembly without the need for extra hardware, keeping things simple and efficient.

4. Printing, Testing, and Iteration

Printed enclosures with tested threaded inserts

Once your design is finalized, it’s time to print. Adjust your settings to ensure optimal precision and quality, and once printed, test the fit of your electronics. Need to make adjustments? That’s the beauty of 3D printing—quick iterations allow you to refine the design and reprint in no time.

With 3D printing, you can speed up the development process, test designs quickly, and save on costs, all while enjoying the flexibility to iterate on the go. By using tools like Fusion 360, high-quality resins, and reliable inserts, you’ll be prototyping your next electronic device with ease.



Dan Kreisher

Hi, I’m Dan Kreisher, Co-Founder of Form(X), a manufacturing and fabrication company based in Central Pennsylvania. Over the past 15 years, I’ve had the opportunity to work in various areas of manufacturing, from CNC machining and laser cutting to 3D printing and custom automation. I’m passionate about problem-solving and helping businesses turn their ideas into reality, and I love the variety of challenges that come with this field.

Before starting Form(X), I spent 10 years teaching engineering and technology to high school students, which was a rewarding chapter of my life. I also earned a master’s degree in instructional technology during that time. While I enjoyed teaching, my heart has always been in the industry, designing, building, and creating.

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