Port Housing Design for Durable Interface Protection

Project Overview

This project features the design and fabrication of a sheet metal port housing bracket engineered to safeguard electrical connectors in a demanding environment. The bracket provides robust physical protection against impact, dust, and moisture while maintaining easy access for maintenance and cable routing. Its layout includes multiple cutouts and raised protective covers to accommodate various connector types, ensuring secure mounting and long-term reliability. Built from corrosion-resistant material, the bracket is optimized for durability, thermal stability, and integration into industrial or automotive assemblies.

The project began with an analysis of the connector’s geometry, required tolerances, and the surrounding device enclosure. Because the housing needed to integrate seamlessly while maintaining precise alignment, early CAD exploration focused on establishing clean reference surfaces and consistent wall thicknesses. These foundations ensured that the port remained stable under insertion forces and repeated use.

A key feature of the design is the integrated connector cover, created to shield the port when not in use. Multiple hinge and latch concepts were evaluated, including flexible living hinges, snap-on caps, and rotating closures. The chosen design incorporates a reinforced hinge area with controlled flex characteristics, allowing the cover to open easily while returning to a secure, seated position when closed. Material selection played a vital role in maintaining durability, dimensional stability, and smooth rotational behavior.