Enclosure Design

Durbable Housing

KEK engineers enclosures that protect complex electronics, meet environmental requirements, and survive real-world conditions. From handheld comms to rugged gateways, we design for manufacturability, thermal performance, and IP compliance from day one.

Councilrock networking device
GE MDS Orbit MDR Router
Councilrock networking devices
Enclosure Design

KEK helps hardware teams turn demanding requirements into enclosures that hold up in demanding environments. Together with our clients, we design rugged housings that are as durable as they are manufacturable.

Our Process

Phase 1
Product Definition
Project Diagnostics
User Research
User Stories & User Needs
Visual Brand Language
Product Requirements
Concep Ideation
UX & Usability Goals
Configuration & Workflows
User Evaluations
Design Strategy & Brief
Traceability Matrix V1
Phase 2
Design & Development
Design Intent & Prototypes
Engineering Development
Engineering Analysis / FEA
DFMEA
Development & Alpha Prototyping
Engineering Testing
Formative User Evaluations
Development & Alpha Prototyping
Engineering Testing
Formative User Evaluations
Design Specifications
Traceability Matrix V2
Phase 3
Design Verification
Build Beta Prototypes
Test Plan & Protocols
Qualification Testing
Support Test Labs (60601)
Design Freeze
Final Design Specifications
Traceability Matrix V3
Phase 4
Transfer to Manufacturing
Production Support
HF Validation
Councilrock networking devices

What We Design For

Thermal Management:
Thermal Management: Passive and active cooling strategies, proven through functional prototype testing
IP & ingress protection
Sealed for dust, water, and full immersion, rated to IP66, 67, and 68
RF integrity
Shielding and connector strategies that keep signals clean in high-interference environments
DFM & material selection
Sheet metal, machined aluminum, injection molding, cast metal, or overmolding, matched to the program
Mounting & interface
Wall, pole, rack, and vehicle mounts, with connector layouts built for serviceability
Board packaging
PCB orientation, thermal interface, and connector routing solved within tight volumes

Areas of Expertise

Models and Prototypes

We build models that move beyond appearance—tools that validate function, assembly, and real-world use. From quick iterations to refined prototypes, each step is designed to uncover issues early and push ideas forward with confidence.

Usability Testing

We observe how people actually interact with products, identifying friction points that aren’t visible on paper. These insights directly inform design decisions, ensuring products feel intuitive, safe, and easy to use.

Electrical Engineering

We integrate electrical systems early in the design process, aligning performance and reliability requirements with real-world production constraints to ensure robuste and dependable operation.

Heat Analysis imagery
Mechanical Engineering

We design mechanical systems with manufacturability in mind from the start, ensuring form, structure, and constraints are resolved early. This allows us to create solutions that are both functional and ready for production.

Human Factors Engineering

We design with the human body in mind, shaping products that feel natural and reduce strain over time. Every interaction is considered to improve comfort, control, and long-term usability.

UI/UX

We create interfaces that guide users without confusion or hesitation. By focusing on clarity and flow, we ensure digital interactions support the product experience rather than complicate it.

Talk to our team

We're Always Looking for a challenge

From concept to manufacturable — hardware design that actually works in the real world.

Portfolio

Featured Work