Case Study: AEInnova develops self-powered wireless sensor housings with Protolabs

AEInnova Development of critical component for self-powered wireless sensors

AEInnova, a developer of self-powered wireless sensors, needed a prototype housing for its InduEye device that could both conduct heat for thermoelectric power and protect the electronics inside. The challenge was to create a high-quality, production-ready part with specific geometries that could withstand extreme industrial conditions, including high temperatures, chemicals, humidity, dust, vibrations, and ATEX environments. Protolabs supported the project with custom prototype manufacturing using CNC machining and plastic injection moulding with overmoulding.

Protolabs produced the metal base insert by CNC machining and overmoulded it with PPS+GF40 plastic to create the finished housing, while also advising AEInnova on geometry and material choices. The result met the customer’s quality and durability requirements, arrived on a tight deadline, and is now being tested in 18 pilot devices in real industrial environments. AEInnova reported strong satisfaction with Protolabs’ reliability, technical guidance, and final finish, and plans to continue working with Protolabs on smaller housings for future versions of the product.

AEInnova

David Comellas

Chief Executive Officer