Custom Plastic Fabrication for DIY Enclosure Using SparkFun Components

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Hey everyone,

I’m working on a project that combines SparkFun electronics with a custom-enclosure build, and I could use some advice on custom plastic fabrication.

What I’m Building

  • Using SparkFun components: (e.g. a RedBoard, a Qwiic sensor, OLED display)

  • Want to house them in a custom enclosure that fits nicely, protects the circuitry, and looks clean

What I’m Considering

  • Materials: ABS, polycarbonate, or acrylic

  • Fabrication methods: CNC routing, laser cutting, maybe vacuum forming

  • Design issues: access to connectors, ventilation, mounting the PCBs securely

What I’d Love Feedback On

  1. What material is best for durability + ease of fabrication + protection from moisture or dust?

  2. Laser cut vs CNC — pros/cons, especially for small-batch enclosures

  3. Any SparkFun “friendly” shops/services you’ve used or recommend

  4. Design tricks you wish you’d known early (e.g. for mounting, strain relief, sealing)

Thanks in advance — I’d love to see pics if others have done similar builds. Always great to learn from folks who’ve already gone through it.

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What, specifically, would you like advice on? We are equipped to handle queries for Sparkfun products

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