Movement is handled via two anodized aluminum handles located on the front, made from an extruded profile with an 8 mm diameter, directly screwed to the drawer.

The drawer’s sliding mechanism was designed to ensure simplicity and cost containment, without using ball bearing guides but instead relying on Teflon membranes applied to slides fixed to the chassis.

To avoid forces or pressures that could deform the front panel housing the connectors, two triangular supports were created to maintain a 90° angle between the front and base, ensuring the safety of the soldered connections on the board.

The drawer can be fully removed from the chassis or left fully extended for complete accessibility without the risk of falling, thanks to a Z-fold serving as a safety stop with a mechanical catch.

In the closed position, the drawer must maintain continuous contact along its entire width with the chassis to ensure homogeneous EMS shielding. For this reason, a compressed counter-fold was created to reinforce and compensate for any errors, ensuring perfect adhesion of the conductive gasket.

The front of the drawer is covered with adhesive polyester and screen-printed with all the necessary graphics for connector identification and company branding.

The application of the polyester is carried out using specific centering equipment with pins and mechanical references to guarantee the correct position and absence of trapped air bubbles.

To ensure better adhesive adhesion, the mechanical components undergo an industrial washing cycle after the cutting and bending processes to eliminate residues of oils and dust.

The product is supplied complete with all assembled components, ensuring that the customer only needs to handle the electronic part of the device and the testing phase.

Shipping is done in certified ESD boxes, allowing the product to be introduced directly into the production system for subsequent stages while preserving the other electronic components from harmful static currents.

This system consists of 6 different materials:

• Pre-treated steel (Magnelis®) with a thickness of 15 mm for the drawer body.
• Galvanized steel for the fasteners securing the electronics.
• Brass for the spacers used in securing the screen protector.
• Transparent VIVAK polyester for the screen protector.
• Polyester with printed graphics for the front label.
• Extruded aluminum alloy 6060 for the handles.

The result was achieved using 9 different technologies: extrusion, profile cutting, deburring, laser cutting, bending, fastener application, turning, screen printing, and final assembly.

elmec decided to manufacture the product entirely in aluminium alloy to minimise its weight. It also optimised the space inside the case as much as possible in order to achieve the most compact solution possible.

Since the product can be used as a table-top application, the central body has been designed to be raised above the tabletop by means of supports integrated within the structure of the device. A detachable kit has also been added to make DIN rail mounting possible.

elmec has designed a solution consisting of only five structural elements, so that the product is easily assembled and accessible for maintenance once in operation.

The two fans provided have been positioned on the bottom and on the inner vertical wall of the device, for suction from the outside and drilling. The raised position of the central body with respect to the top will allow better ventilation and increase the incoming air flow, improving the operating conditions of the electronic part. A perforated area has been provided on the upper side of the enclosure for the escape of hot air.

An ad hoc solution has been provided, which couples ventilation with easily replaceable filters: the system prevents dust or other particles in the environment from being attracted into the device. [which requirement are you referring to? electromagnetic compatibility?] All perforations made in the mechanics ensure the correct circulation of air flows, but are designed to be less than 4 mm in diameter.

The product is made entirely of 5000 aluminum alloys. The result has been obtained by using technologies of laser cutting, milling, mechanical satin finishing of surfaces and fasteners application. Complete all a chromating treatment SURETC 650 as preparation for liquid painting of the side surfaces of the body. The front and rear panels have been treated with black anodizing to make them resistant and suitable for handling In Out. The external treatments have been realized through our consolidated network of external resources.

The application required achieving an IP67 rating for the front frame to ensure safe use in installation environments.
This feature can be obtained by addressing key factors of the aluminum frame to ensure bonding with the front display glass.

• Flatness of the frame
• Adequate roughness of bonded surfaces
• Distribution of fixing points

Correct flatness is achieved by avoiding excessive deformation of the front bezel. The factors contributing to deformation include material selection, milling approach, and specific adjustments to the application of PEM press inserts. 

The use of gaskets requires special attention to ensure uniform pressure on the perimeter. A study of the HMI panel’s fastening system to the supporting structure was necessary, with holes distributed at the high-load points in proportion to the dimensions of the rear casing, ensuring proper sealing of the gasket. 

Finally, to protect against external falling elements, a top cover was created to shield the rear box containing the electronics.

The project had to consider existing constraints:

• Predefined external dimensions
• Predefined internal electronics dimensions

We designed a structure that acts as a “tailored suit” for the device. 

Particularly, to maintain a fixed depth, the box was designed with deformations on the sheet metal via stamping to house and protect the bulkier components without affecting the overall volume. 

This solution, creating a custom fit for the internal electronics, required the development of dedicated stamps for the necessary deformations with the aid of 3D laser cutting technology, allowing processing at every surface level.

Additionally, the design of these stamps was also studied for future 7” and 15” HMI systems to optimize the solution across product versions. 

Another important solution to accommodate the electronics while maintaining dimensional constraints was the creation of custom spacers for the board support, overcoming the limits of traditional standard systems available on the market. 

The press-fit sheet metal spacers were made of stainless steel 303 and brass to ensure proper holding on different laminated supports.

The choice of the most suitable material for creating a mechanical system is made by considering multiple aspects:

• Product usage conditions
• Compatibility with technologies used for processing
• Aesthetic parameters of the finished product
• Costs

The true goal lies in finding the right balance between the various needs. 

The rear box, being recessed, was made of pre-galvanized steel, the best compromise between functionality, electrical conductivity, resistance to corrosion over time, and cost-effectiveness. 

For the front frame, we opted for aluminum alloy 5005, with milling and subsequent natural oxidation treatment, ensuring lightness and a good aesthetic finish resistant to operator use.

This system consists of five different materials (aluminum, pre-oxidized aluminum, pre-galvanized iron, stainless steel, and brass). 

The result was achieved using 13 different technologies (punching, milling, stamping from mold, assembly and application of press inserts, bending, satin finishing, turning, silk-screening, welding, industrial washing, laser cutting, 3D laser cutting, and mold construction), 5 of which were sourced from our trusted network (oxidation, silk-screening, 3D laser cutting, turning, and dedicated mold construction).

1. 5 Materials

2. 13 Technologies

3. 7 Core processes