Portable Secure Communications Device — Mechanical Product Design

Designed a compact, production-ready mechanical enclosure for a portable handheld communications device intended for professional security applications. The brief was to maintain the pocketable form factor of a conventional power bank (90 × 60 × 25 mm) while packaging high-density electronic assemblies, an internal rechargeable battery, and multiple RF modules without compromising structural integrity or manufacturability.

Our engineering team was responsible for the complete mechanical product development, including: • Industrial enclosure styling & internal structural framework • PCB mounting architecture & battery compartment integration • Display mounting system, button placement, and ergonomic layout • Heat dissipation vent design & waterproof enclosure sealing • Snap-fit and precision mechanical joint development • Structural reinforcement for vibration-free component retention • Manufacturing-ready assembly documentation & BOM

The defining constraint was thickness: 25 mm or less total profile. Inside that tight envelope we packaged: • 16650 rechargeable battery cell • Multiple RF transducer modules • Control PCB & interconnects • Mechanical fastening bosses & snap-fits • Structural wall thickness & manufacturing tolerances • Passive heat dissipation channels Because the client explicitly prohibited active cooling solutions such as fans, thermal performance had to come from ventilation geometry alone without compromising the sealed, rigid assembly.

Developed in Autodesk Fusion, the mechanical package includes approximately 12–15 custom mechanical components. Deliverables provided to manufacturing partners included: • Native CAD files & STEP models • Production drawings & detailed assembly drawings • Exploded assembly views & DXF profiles • Complete Bill of Materials (BOM) & rendering assets • Step-by-step assembly documentation

A functional prototype was manufactured using precision 3D printing to validate component clearances, snap-fit engagement, and assembly ergonomics. Following prototype evaluation, two mechanical design revisions were completed before final client approval. The finalized design entered commercial production, with an initial manufacturing batch completed and larger follow-on production orders subsequently placed.

The project was executed in close collaboration with RF engineers, electronics teams, industrial designers, and manufacturing partners. Successful delivery resulted in a 4-year engineering support agreement and led to additional follow-on engineering engagements from the same international client.