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This black shell is the housing of a desktop router or small network switch. The circuit board, the power jack, the RJ45 ports and the status lights all live inside it, and the perforated field on the top cover is what lets the chipset breathe. It is a two-part injection molding: a top cover and a base that close on a parting line around the middle and hold with self-tapping screws into moulded bosses.
The housing is molded in black PC/ABS as two shells. The top carries the vent field and the port openings; the base carries the bosses, the label recess and the feet. Dimensions follow the PCB and the connector stack, so the housing is really a mechanical adapter between the electronics and the desk. This page covers the split, the vent field, the port openings and the resin choice.
The parting line runs around the waist of the housing, low on the side wall, so the seam sits where the eye least expects it. The top cover is the show surface; the base is the working surface. Four screw bosses rise from the base corners, and the screws pass into the cover’s ribs from below, which keeps the top face free of fastener marks.
The bosses are cored rather than solid. A solid boss at the corner of a flat base would sink, and the sink would telegraph through to the desk as a wobble. Cored bosses keep the section near the wall and the base flat, which matters more than it sounds: a router that rocks on the desk reads as cheap no matter how well the rest of it is molded.
The dotted field across the top is several hundred small moulded holes. Each one is a tiny core in the tool, and the whole field is a manufacturing decision: hundreds of cores cost tool maintenance, vent cleaning and inspection effort, in exchange for passive cooling that needs no fan. The holes are drafted so the cores release cleanly, and the field is kept away from the parting line, where a burr on one hole edge would catch a fingernail and read as a defect.
There is a trade-off worth naming. Denser holes mean more cooling and more tool risk; sparser holes mold faster and stay cleaner longer. The customer’s thermal budget decides the density, and the tool is built to the drawing rather than to taste.
The openings for the RJ45 jacks, the USB port and the DC jack are cut where the connectors land on the PCB, and their positions are held against the board layout, not against the housing drawing alone. A port that sits half a millimetre off shows as a plug that will not seat, and the customer finds it at final assembly, which is the expensive place to find it. We mold first articles with the customer’s board drawing and check every opening against the connector positions.
The front face carries the slot for the status window. It is a shallow recess rather than a through hole, so the light pipe sits behind the wall and the shell stays closed. Light pipes need a clear, unfilled zone behind them; a thick wall or a rib in that zone scatters the light and the indicator reads dim.
PC/ABS is the default for this class of shell: PC brings stiffness and heat resistance for a device that runs warm, ABS brings flow and finish, and the blend molds black to a uniform matte without streaks. Where the customer’s specification calls for a flame-retardant grade, the compound changes and so does the shrink — the mold is cut to the grade, not to a generic value, because FR resins move differently in the tool.
Black hides a lot, but not everything. Flow marks and gloss variation still show on a wide flat surface under office lighting, and the vent field makes the surface busier, not cleaner. Gate position and packing are tuned on the show face first; cycle time is optimized after the appearance is right, not before.
Kunshan Maifeng Precision Industry Co., Ltd. reviews network device housing designs before quoting, builds the injection molds in house, and molds single-color and dual-color parts on 36 machines from 90 to 700 tons. Send us the PCB drawing and the housing 3D model, and we will come back with a feasibility comment and a tooling proposal.
Kunshan Maifeng Precision Industry Co., Ltd. (MIF) has an investment of RMB 35 million and an independent factory of more than 5,000 m². The company operates 36 single- and dual-color injection molding machines from 90 to 700 tons, together with more than 50 sets of mold manufacturing and processing equipment. Our service, management and production team includes over 100 people.
Our parent company was established in 2008. We provide product design, mold design and manufacturing, injection molding and product assembly services for custom plastic parts, supporting both domestic and international customers.
1. Product Design
Product structure design and optimization based on customer drawings and samples.
2. Mold Design
Mold design developed around product geometry, material and production requirements.
3. Mold Manufacturing
Machining, polishing, fitting and assembly for custom injection molds.
4. Injection Molding
Single- and dual-color injection molding for project and order requirements.
5. Product Assembly
Supporting assembly services for molded plastic components.
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