General Project Context

• As part of our smart HVAC system, we need a physical enclosure to house the custom controller PCB designed by a parallel student team. This enclosure will be installed in utility rooms, and must support heat, electromagnetic interference, and user-friendly access.

Project Brief

• You will design a 2-piece enclosure (base + cover) that safely houses the controller board while exposing necessary ports and indicators in precise positions.
• This project must be developed in coordination with Project A: Smart HVAC Controller PCB Design. The board’s orientation and layout define the exact port/cutout placement for your enclosure design.

MANDATORY Board Orientation:

• Front of Enclosure (facing user):
• Push button
• 4x LEDs (Green, Blue, Yellow, Red) — must shine through a translucent or thinned wall
• USB-C port access
• Back of Enclosure (wiring side):
• AC Power IN terminal block
• Common IN terminal block
• 4x 24V AC relay output blocks (NO)
• 3x double terminal blocks for 5V DC slave output (Power + Common)
• Ethernet RJ-45 port
• Sides:
• Blank (no ports or mounts)
• All components must be easily accessible from outside the housing. The enclosure must fit this board exactly with proper clearances and support structures.

Mechanical Requirements

• Magnetic mounting support (4 magnets, one per corner, no EMI interference)
• Robust yet compact design for furnace room mounting
• Support for CNC or 3D print prototyping
• Wireless signal friendliness
• Field-serviceable access for wiring

Deliverables

• 2–3 enclosure CAD designs (STL or Autodesk Fusion)
• Full mechanical layout with port cutouts, standoffs, internal fit
• Photos or description of basic 3D print/CNC prototype (if feasible)
• Testing report: thermal, wireless signal permeability, durability
• Material/manufacturing recommendations (plastic, metal, injection molding, etc.)

Student Learning Outcomes

• Real-world product design for embedded systems
• Thermal, electromagnetic, and mounting constraint navigation
• Collaboration with electrical/embedded engineers
• Design for manufacturability and practical installation