Frequently Asked Questions

Essentially, you should have a sense of what you need designed. It’s okay if you don’t know all of the specifics. But to start, it helps to supply things like rough sketches, data sheets, photos or drawings. You should let us know if you have a specific material in mind for your project (as well as a corresponding thickness, if you know that already).

Yes. We'll provide a price quote based on the information you give us. If the scope of the project changes, we may need to adjust the estimate.

For an affordable hourly rate, our Engineering & Design Services team will review your sketch, description, or components to create a professional, manufacturable CAD design and deliver the final file. Read more here.

This service is perfect for you if you need to bring a design idea to life, design an enclosure around components, or create or convert a CAD file from an existing part or PDF.

Yes. While customers typically use Protocase’s one-stop custom manufacturing for their parts, you may also take your design once finalized to another manufacturer. Remember – you own all parts of the design(s) created with Protocase Design Services.

Yes. Our Engineering & Design Services team can work from your initial concept, which can be anything from a simple sketch or verbal description to a set of components and boards.

An eDrawing is a file (either e-drwg, easm or eprt) that allows you to view a 3D model of the enclosure. It provides clients the ability to verify dimensions, view the enclosure from all angles, view section cutaways to inspect the inside and dissemble the enclosure to view each part that makes up the assembly

We use eDrawings for the design approval process – you must approve the eDrawing before we can proceed with manufacturing the design.

Yes. You’ll receive an eDrawing for approval before production begins.

Protocase Designer is our easy-to-use design software that lets you design and order custom parts, enclosures, panels, and brackets in minutes. Find more about Protocase Designer here!

• .sldprt, .sldasm (Solidworks Pack & Go)

• .pda (Protocase Designer)

• .stp (STEP file)

• .igs (IGES file)

• .x_t (Parasolid)

• .asm (ProE 3D assembly and part files)

• .sat (AutoCad 3D assembly)

• .dwg (AutoCad 2D assembly)

• .dxf (AutoCad 2D assembly)

Head over to the “Quotes” section in My Account to review and manage your quotes and even place orders.

• For lightning-fast pricing, use our Instant Quoter. Simply upload your design, and you'll have a quote in seconds.

• For more complex projects, our Request-a-Quote form lets you add detailed requirements. Our team will follow up with a quote within one business day.

• If you're using Protocase Designer, you can get an instant quote right away as long as your design passes manufacturability checks!

• You can also email info@protocase.com with the details of your project (including any 3D design files created).

Yes. Each customer is assigned an Account Manager to help with design, pricing, ordering, or any other assistance you might need. To get in touch with your Account Manager, fill out the form on our Contact page or email us at info@protocase.com.

Lead times can adjust according to a number of factors, including using non-stock materials and components, large quantity orders, welding, chemical conversion coating, or orders that have multiple silkscreened graphics. Contact us at info@protocase.com to discuss your needs.

Yes, absolutely! We are happy to sign NDAs at your request. Just select the option while onboarding in My Account or ask your Protocase account manager.

You can add your organization's details and upload important documents in the "Onboarding" section of My Account. This information can be edited at any time. If you'd like to onboard another way, your Account Manager can help.

No, we never enforce a minimum order quantity. You can order a single part if you wish to.

We offer two options:

• Priority Service Stream: 2-3 days (for orders with in-stock materials and in-house services)

• Economy Service Stream: Three weeks

Traditional job shops operate on a backlog-based model, meaning lead times vary widely depending on their queue. Quality can also be inconsistent, and many shops still rely on manual quoting and analog communication, making the process of getting custom metal parts slow and complicated.

Protocase's High-Velocity Mass Customization (HVMC) model offers a solution. You get fully custom parts from a single source, eliminating the need to coordinate with multiple shops. We offer lightning-fast, fixed lead times of 2-3 days, consistent quality, and digital tools that make ordering as easy as shopping online.

Learn more about HVMC here.

Protocase is for scientists, engineers and innovators who need custom parts and enclosure for experimental development and rapid prototyping.

Protocase manufactures custom electronic enclosures, sheet metal parts and CNC machined components. Parts are manufactured to order based on your design, within just 2-3 days.

In My Account portal, you get 24/7 real-time updates on your orders – even on weekends and holidays. Head to the 'Active Orders' tab to see your order's current status. You can get in touch with your Account Manager at any time if you have questions.

Yes, you can access a detailed proforma invoice inside My Account instantly after placing your order.

There's no need to start from scratch or dig through old emails to do that. With the My Account portal, reordering is easy.

If there is a problem with the product, please contact us right away. We will replace, at no cost, any product not manufactured in accordance with client-approved eDrawings or any product not deemed to be of acceptable quality to both Protocase and the client.

We ship priority orders by express courier and other orders by economy courier unless otherwise agreed upon. Protocase cannot be held responsible for courier delays or damage in shipment once the product has left our facility.

Protocase ships worldwide!

Shipping is included in the quote unless explicitly stated otherwise.

Our default currency is in USD. However, if you would find it more convenient, we can quote, invoice and accept payment in CAD, GBP and EUR. Pricing in alternate currencies will be based on the USD price, using our effective conversion rate, and we will hold alternate currency pricing for 30 days. For more information, email info@protocase.com.

Our standard payment terms are as follows:

• First Order: Prepayment

• Repeat Orders: Prepayment

• Net 30 Terms: Net 30 accounts may be arranged on approved credit. Contact your Account Manager to get the NET 30 application.

We accept payments via Credit Card, Wire, PayPal, E-Transfer, Cheque/Check, ACH.

Once you have a price quote, you can order in a few different ways.

• My Account: Use our secure self-serve portal to order and reorder projects.

• Protocase Designer: If you created your design in Protocase Designer, you can order directly through the software.

• Through an Account Manager: Fill out the Contact Us form on our website or email info@protocase.com.

Yes, we do. JIT (Just in Time) Production or Standard Blanket Order is the best option if you have a custom design that you want manufactured in low- to large-volume quantities on a regular basis within a 12-month period.

Yes, in that case, the Protocase Blanket Order Program is the perfect solution. Learn more here.

The Blanket Order Program offers volume pricing without requiring you to get all your parts or enclosures manufactured at once. It also eliminates the risk and cost associated with holding unnecessary inventory.

Choose a Prototyping Blanket Order if you're developing a new design and are not yet certain it will meet your project's final requirements. It's the ideal choice for testing initial designs.

Opt for a Standard Blanket Order if you have a finalised custom design that you need manufactured regularly over a 12-month period. Also known as Just-in-Time (JIT) delivery, this option is best for consistent, scheduled production in low- to large-volume quantities.

3D printing is an additive process, meaning material is built up layer by layer. In contrast, CNC machining removes material, and sheet metal involves cutting and bending.

Within 2-3 business days.

No. You can order a single part or scale up to higher volumes as needed.

All of the information is available on the 3D Printing page on our website.

3D printing is ideal for rapid prototyping, product development and creating complex internal components such as brackets, PCB mounts and supports for enclosures.

Protocase's 3D printing uses fused deposition modelling (FDM), which involves heating the filament and then depositing it by an extrusion head onto a build platform where it cools off.

Yes, we do. Learn more here.

Of course, we can. We are happy to ordering non-stock materials; however, this may result in additional lead time and increased cost.

Yes! We can install components during the manufacturing process:

• PEM Hardware: Installed during punching/forming
• Standoffs: Press-fit or welded
• Gaskets: Applied during assembly
• Labels/Graphics: Applied before shipping

This saves you time and ensures precise placement.

You can find detailed information about our materials, including all of the customization options available on our website here.

We stock translucent plastics, acetal and UHMW Polyethylene. We can work with plastics in terms of our CNC machining, or by installing clear windows on a custom sheet metal enclosure.

Stocked materials include aluminum, steel, stainless steel, copper, galvanneal, perforated sheet metal, aluminum bar stock, stainless steel bar stock.

Protocase offers a wide range of finishes for both functional and cosmetic purposes. These include powder coating, chemical conversion coating, anodizing*, Resicoat, tin plating*, nickel plating*, and bare metal finishes like grained, vibratory, and media blasting.

*Please note: These processes require additional lead time as they are completed off-site by our trusted third-party suppliers.

The best finish depends on your application requirements, including corrosion resistance, aesthetics, conductivity, durability and environmental exposure. Contact us if you need help selecting the right finish for your specific requirements.

Masking protects specific areas from coatings or anodizing to preserve tolerances, grounding surfaces, or conductivity zones.

Passivation is the process of treating stainless steel with Citric Acid in order to remove free iron from the metal's surface.

A bare metal finish is a great option if you don't want your parts painted but still want them to be aesthetically pleasing.

Protocase offers several bare metal finishes for custom parts, enclosures and panels, including no finish, grained finish, vibratory finish, media blasting, stock finish.

Chemical conversion coating is used on aluminum parts and enclosures to improve corrosion resistance while maintaining electrical conductivity.

Yes. In fact, we recommend it. Chemical conversion coating will not hide any existing scratches or blemishes on the surface of unfinished aluminum parts.

Yes, chemical conversion coating is also known as chem film, chromate coating, or yellow chromate coating.

Anodizing enhances aluminum's natural oxide surface, providing increased corrosion resistance and a decorative finish. It serves both functional and cosmetic purposes.

Anodized aluminum's surface is also much harder than untreated aluminum, and is therefore much more resistant to scratches and wear.

The key difference between Type II and Type III is that for Type III anodizing, the sulfuric acid solution's temperature is lowered and run at a higher voltage.

The end result is a denser, wear-resistant oxide layer that creates a harder and smoother finish than Type II anodizing. Type III anodizing is ideal for parts that rub together.

Widely recognized as the industry standard for painting metal, powder coating provides a high-quality, durable finish.

Protocase offers a variety of standard stocked colors and textures. Visit our powder coat page for more details.

Yes, we are happy to offer non-stock or fully custom colors for an additional fee and a longer lead time. Please contact us for more information.

Yes, we can provide free samples so you can see the actual colors and quality up close. This will help you make an informed decision. Request your samples here!

Yes, but please note that this requires additional lead time as these processes are completed off-site by trusted third-party suppliers.

We offer two resicoat options: Resicoat® EL HGD47QF ECA-1283 Red 3332 and Resicoat® EL HNF35QF ECB-1363A Black 2701.

Yes, we cannot accept .CDR (Corel Draw) files.

To ensure the highest print quality and clarity, vector graphic files are recommended:

• .AI - Adobe Illustrator

• .EPS - Encapsulated PostScript

• .SVG - Scalable Vector Graphics

• .PDF - Portable Document Format

• .DXF or .DWG - AutoCAD

We can accept the following raster image files (however, additional processing charges may apply):

• .PNG - Portable Network Graphic

• .JPG (.JPEG) - Joint Photographic Experts Group

• .TIF (.TIFF) - Tagged Image File

• .PSD - Photoshop

• .VDX, .VSD, or .VSDX - Visio

• .DOCX - Microsoft Word

• .PPTX - Microsoft PowerPoint

Laser marking, machined engraving, engrave and fill, dot peening and rubber stamping are all recommended for MIL-STD-130 applications.

Yes, we can add serial numbers as part of our custom manufacturing process. Our methods include laser marking, engrave and fill, machined engraving, dot peening, rubber stamping and Avery labels. We can also add serial numbers using graphic techniques like silkscreening and digital printing.

The best marking method depends on your project requirements. Digital printing is ideal for detailed multicolor graphics, silkscreening works best for sharp single color designs, while laser marking and engraving provide permanent identification.

Laser marking, machined engraving, engrave and fill, and dot peening are all considered permanent marking methods suitable for industrial and military applications.

720 DPI is ideal for standard labeling and graphics, while 1440 DPI is recommended for highly cosmetic applications, large gradients, and customer facing products.

Our standard CNC machining tolerances are:

• Standard: ±0.005" (±0.127mm)
• Precision: ±0.002" (±0.05mm)
• High Precision: ±0.001" (±0.025mm) - additional charges may apply

Tighter tolerances are available upon request. Please specify critical dimensions in your drawing.

You can check out our guide that compares digital printing and silkscreening.

We offer several types of laser marking, each with a unique look and feel. Our options include engrave, burn, silver, outline, ablate and anneal.

Yes, depending on your design requirements, you can use more than one type of laser marking on your custom enclosures, parts and panels to achieve your desired aesthetic.

Self-clinching fasteners are threaded nuts, studs, or standoffs that are mechanically pressed into sheet metal to provide solid fastening points.

Yes! Welded assemblies can absolutely be powder coated. We recommend:

• Grinding welds smooth for best appearance
• Using same material type for consistent finish
• Considering weld seam location in visible areas

Our team can advise on the best approach for your specific application.

Protocase offers piano hinges, lift off hinges and adjustable torque position control hinges.

We stock AS9100 Certified and RoHS Compliant gasket materials in-house. We're also happy to source non-stocked materials for you if needed.

We can either ship standalone gaskets directly to you, or we can save you a step and install them onto your custom enclosures.

Flush-head fasteners are mechanically pressed through a hole in sheet metal to provide a solid fastening point. While the fastener will sit fairly flush with the sheet metal once inserted, there will be slight indentation around the fastener in the material where the fastener sits.

Meanwhile, concealed-head fasteners are not inserted through the sheet metal. They are instead mechanically pressed into a pocket (created by a CNC router or CNC mill) in the sheet metal. Because it is not a through-hole fastening point, the fastener is not detectable whatsoever on the exterior surface of the sheet metal.

Rivets fasten two parts together through a concentric hole. The end result is a simple, aesthetically pleasing look that is durable and strong.

Protocase stocks a wide variety of studs in different lengths and threads. Click here for a complete list of our stocked and non-stock studs, though this is subject to vendor availability and may affect lead times.

Yes. If a component is not stocked, Protocase can often source it from our trusted suppliers. Some non-stock items may require minimum order quantities and could extend lead times.

We stock both short and long heat-set inserts. Click here for more information. If you require another type or thread size insert, please contact us with your request.

We offer a wide variety of handles, but our most popular options are the small chrome, medium chrome and large plastic handles.

We have four common styles: small, medium, large, and taper.

We recommend small feet for enclosures under 10" (254mm), medium feet for those under 15" (381mm), and large feet for anything bigger. You should only use taper feet if you don't have enough interior space for the attachment studs and nuts required by the other sizes.

We don't recommend taper feet unless there is no room to accommodate attachment studs and nuts required by small, medium or large feet.

Countersinking is ideal for ensuring your flathead screws sit flush against the metal of your custom enclosure or part.

We offer spot welding (a great option for permanent assembly) and seam welding using Cold Metal Transfer (CMT).

Yes, both spot welding and seam welding are standard processes that make up our 2-3 day manufacturing lead time.

We can weld cold rolled steel, galvanneal, stainless steel, aluminum and copper*.

*Copper is usually brazed.

Spot welding is a fast and efficient method for permanently joining two pieces of sheet metal in one or more spots.

Meanwhile, in seam welding, two pieces are clamped securely and welded, and then any excess metal is removed by grinding. The end result is a continuously joined seam.

At Protocase, we use Cold Metal Transfer (CMT) welding. While it appears similar to wire-feed MIG welding, there are differences:

• In MIG welding, filler metal transfers via sputtering at very high temperatures.

• In CMT, the wire is heated enough to melt the tip, and transfer occurs by physical contact. This method generates just one-tenth of the heat of MIG welding, which prevents warping or melting back, even for thin sheet metal.

No, not all designs require welding. Many enclosure types, such as our standard U-shape (clamshell), do not.

At Protocase, we use Cold Metal Transfer (CMT) welding. While it appears similar to wire-feed MIG welding, there are differences.

In MIG welding, filler metal transfers via sputtering at very high temperatures.

In CMT, the wire is heated enough to melt the tip, and transfer occurs by physical contact. This method generates just one-tenth of the heat of MIG welding, which prevents warping or melting back, even for thin sheet metal.

We have very few limitations on the cutouts we can create. As a general rule, if you can design it, we can create it for your custom part.

The minimum distance a cutout can be located from a bend is driven by the material type, thickness and tooling used to bend or bend radius required. You can refer to our Material Bend Radii and Minimum Bend Size Chart to determine the ideal value for your design. If you have additional questions, please contact us.

Dimple Forming involves pressing the edge of the hole between dimple dies to form a beveled/flared edge.

There is no limit to the number of cutouts. As a rule of thumb, cutouts should be at least 1.5 times the material's thickness away from any other cut. However, this can vary in practice. Keep in mind that parts with many cutouts may warp due to heat and/or the relief of residual stress inside the metal. Contact us if you encounter such situations when designing.

Louvers are an excellent feature for providing ventilation in your custom enclosure. They allow air to flow while still offering protection against the accidental entry of dirt, dripping water, or other foreign objects.

Material must not exceed 0.1285" (3.264mm) in thickness.

Yes, we support student engineers and designers with the Protocase Student Sponsorship Program. Student engineers and designers with research and education projects (as well as graduate students on a need basis) can apply to have Protocase manufacture professional-grade custom enclosures and sheet metal parts. If you meet our criteria, we can fund all or part of your project, up to $500 annually.

Send an email to info@protocase.com with information about your project, including your financial need, timeline and the desired parts you'd like manufactured.

Yes! We are proud to be a major sponsor for four premiere competitions: the University Rover Challenge (URC), the Canadian International Rover Challenge (CIRC), the International Rocket Engineering Competition (IREC) and Launch Canada.

Protocase Product Inspection Services includes:

• First Article Inspection

• Periodic Sampling

• 100% of Parts Inspection

One of the means by which we provide Inspection Services are through the use of coordinate measuring machines (CMM), which are devices that measure the geometry of physical objects by sensing discrete points on the surface of the object with a probe.

Our Product Inspection Services can objectively inspect all verifiable or quantifiable aspects, including dimensions, finishes, component (presence and placement) and assemblies.

We offer three levels of inspection service: Standard, Basic and Premium. For more details, click here.

Yes, Protocase is ISO 9001 registered and AS9100 certified.

We are also fully compliant with the International Traffic in Arms Regulation (ITAR) and the Canadian Controlled Goods Program (CGP).

Lead times vary depending on part complexity and customization requirements, but Protocase specializes in rapid manufacturing with lead times as fast as 2-3 days for custom CNC machined parts.

Standard Precision: X ≥ ±0.005”(0.13mm)

Premium Precision: ±0.005”(0.13mm) > X > ±0.001”(0.025mm)

Ultra Precision: ±0.001”(0.025mm) ≥ X ≥ ±0.0001”(0.0025mm)

X=Tolerance

Nominal Dimension ± X

Yes. Protocase specializes in custom prototypes and low volume production, including one off CNC machined parts.

Due to the spinning motion produced by the CNC milling machine's cutter, the surface finish of CNC machined parts will have visible toolmarks. If you require a smooth, unblemished finish to your part, we recommend choosing a secondary finish: grained finish (can only be applied to the outside of machined enclosures due to geometry) or powder coat.

Using the largest possible radii for your design will improve surface finish quality and lower machining costs.

Large Radii = Larger Tools = Faster Cuts = Less Time = Lower Cost