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Batch production of enclosure housings for Departure Boards UK

A large, repeatable FDM workflow: stable settings, dried filament, low defect rates, and packaging discipline across a high-volume run.

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Flame finishing a 3D printed enclosure to remove fine PLA strings.

Project snapshot

Item Details
Client Departure Boards UK
Process FDM batch production
Material PLA (single supplier/spec for consistency)
Part format Two-part enclosure (two halves)
Typical assembled size ~14 × 4 × 5 cm
Quantity ~500–600 units
Capacity Up to 16 printers running in parallel
Pricing Commercial terms (confidential)

The brief

Produce a high volume of two-part enclosure housings for portable tabletop “departure board” products. The model was provided by the client and remained unchanged; the focus was reliable manufacturing, consistent finish, and on-time dispatch.

What mattered

  • Consistent fit across the entire run
  • Clean cosmetic finish (minimal stringing and debris)
  • Low defect rates with reliable QC screening
  • Predictable delivery timelines

Production approach

1) Locked material spec + calibrated settings

For high-volume printing, repeatability comes from controlling variables. We used a single PLA spec from one manufacturer and kept settings consistent across the printer fleet: temperature, flow, retraction, cooling and surface finish.

2) Dry filament to reduce stringing

PLA stringing can make parts look messy and increases cleanup time. Filament was dried before printing to reduce moisture-related artefacts.

3) Parallel printing to meet deadlines

To deliver batches quickly, multiple printers ran in parallel. A full enclosure set (part + matching half) printed in a little over four hours at the chosen quality settings.

A translucent green test enclosure printing inside a 3D printer.
Occasional test colours were printed by request, but the main production stayed on a single calibrated material spec.

4) Quality control and finishing

Early batches had a small reject rate (around 2%). QC checks ensured only correct parts shipped, and as the process stabilised the defect rate reduced to effectively zero.

Cosmetic finishing included removing any plastic remnants and a quick flame pass to remove micro-strings.

Flame finishing a black PLA enclosure to remove fine stringing.
A quick flame pass removes micro-strings and gives a cleaner final appearance.

5) Individual packaging and dispatch

Each part was bagged individually and packed securely for shipping.

A large batch of black enclosures individually bagged and ready for final packaging.
Individually bagging parts protects surfaces during shipping and makes fulfillment smoother for the client.
Test enclosure variants printed in different colours and packed in clear bags.
Colour variants were produced as small test runs while the main batch stayed on a locked material spec.
Multiple printed enclosures packed together inside a shipping box.
Batch packing with a consistent process helps keep delivery timelines predictable.

Result

A reliable commercial workflow for repeated production: consistent enclosures delivered in volume with stable quality, QC screening, and careful packing.

Related: Batch & Commercial Orders, FDM 3D Printing, PLA, Get a Quote.

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