Custom Plastic Enclosure Manufacturer No Molds Technology!

Plastic Enclosure Manufacturing Process

No Mold Technology

The foundation of Toolless Process is anchored in our ability to design and manufacture enclosures without the use of hard tooling. The idea of Zero tooling was born out of 90’s economic recession as the result of engineering budget restrictions. One engineer had the idea of adopting the sheet metal process to plastic sheeting eliminating the need for expensive tooling.  Using a simple CNC router, and detailing a technical assembly process, this unique Toolless technology was born.  For entrepreneurs, inventors & engineers this process represented a major change.  Not only did it reduce the budget to create a prototype but it also minimizes the expense to produce low and medium production runs while keeping an aesthetically appealing design.


Because of our unique design characteristic, Toolless is your partner in designing the most attractive design at the most competitive price.


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CNC Machining

The Toolless technology is a CNC machining and fabrication process that uses assembly techniques borrowed from the sheet metal and (wood) cabinet making industries. We use this CNC machining from start to finish from scratch, unlike competitors that use premanufactured enclosures. This allows Toolless to cut the middle man and make the entire enclosure in house. 

The technology is used to make custom plastic enclosures, “hog-out” enclosures, bezels, machined parts and assemblies quickly for fast turn around with our ten step process.

Ten step process

  1. Design the plastic enclosure starting from a dimensioned drawing or CAD file showing the circuit boards and electronic components oriented in space.
  2. Generate the CNC code that drives all the machining and bending operations.
  3. Machine the plastic sheet to add openings, vents and recesses.
  4. Cut individual pieces from sheet.
  5. Prepare joint and edge details on routing machines. All joints feature a modified tongue-and-groove design.
  6. Score the sheet with bending cuts on a custom table saw. These v-shaped bending cuts extend halfway through the sheet and boost the bending precision.
  7. Bend the pieces in a computerized thermal bending machine that resembles a sheet metal brake press.
  8. Heat stake metal inserts into bosses. Install the bosses into machined recesses in the sheet.
  9. Assemble the pieces using a solvent-bonding process.
  10. Perform secondary operations like painting, EMI shielding, and latch or hinge installations.

Your custom enclosures are then shipped out and into your hands quickly.

Advantages over Injection Molding

  • No tooling or capital outlay – No minimum orders
  • Fast turnaround
  • High quality appearance
  • Zero draft  - Zero Tooling
  • Changes are easily incorporated
  • Complex features including bosses, ribs, and interlocks can be added