IR Camera Enclosure Design

This case study is about IR Camera enclosure design.  Traditionally, this type of camera enclosures has unique design requirements. Our clients legacy product had several challenges in the market, hence we were entrusted to re-design it.

Among typical industrial design projects, this had more focus on materials and heat management apart from serviceability requirements and of course aesthetics.

The IR camera enclosure design team, studied the market to set a benchmark and goal for the project.

We made sense of the research to draw insights for our new design. We also studied the trends in a similar product category and created a design theme board for inspiration

After a series of brainstorming, we arrived at a feasible product architecture which was approved by the client to move forward.

Based on the architecture, the team worked on the aesthetics to arrive at multiple options.

Potential ideas were refined to get into the CAD visualisation.

The client made their choices base on the initial challenges, aesthetic trade-offs were made over thermal requirements. Initial CAD designs were 3D printed to arrive at the mark 1 prototype.

Mark 1 – Design with plastic bezel and IR camera window.

After the first DVT, thermal issues still persisted and the team refined the design to build the faceplate in aluminium with the increased surface area for better heat dissipation.

Mark 2 design was prototyped quickly to re-examine the performance. On the left, mark 2 in comparison with mark1 (on the right).

Ceiling mounting box design was unique as the appearance of the metal box looked like plastic injection moulded. We loved it.

This time, the design was very close to the performance criteria and the engineering team closed in for finer engineering refinement to close the design phase of the project.

The look-alike – work alike prototype [mark2], ready for mass production.

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