Scalable Additive-Manufactured Enclosure for 4G Cellular Device.

We worked with vSMSC to develop a production-ready enclosure for an 8-SIM 4G cellular device, designed for deployment in a fast-moving and highly competitive technology sector.

Given the anticipated medium production volumes and rapid pace of technological change, traditional injection moulding was ruled out early. High tooling costs, long lead times, and the risk of poor return on investment through mould amortisation made this approach commercially unattractive. Instead, the enclosure was developed specifically for additive manufacturing, using Multi Jet Fusion (MJF) technology.

Material selection and manufacturing strategy were critical to success. The enclosure needed to be physically robust, suitable for the consumer market, and deliver a high-quality look and feel with a refined surface finish. At the same time, it had to comply with CE and UKCA marking requirements, including successful EMC emissions testing.

The final design was optimised around the strengths of the MJF process – minimising material use, reducing print time, and enabling efficient batch production – while maintaining structural integrity and thermal performance. Design features were carefully engineered to support electromagnetic compliance and consistent repeatability at scale.

The result is a cost-effective, scalable, and regulation-ready enclosure that allows vSMSC to bring their product to market quickly, adapt to future technology changes, and scale production without the financial and operational risks associated with traditional tooling.