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I have always wanted to use PCBs as structural elements for something. They are readily available based on fiberglas and aluminium, can be easily designed to wh

I have always wanted to use PCBs as structural elements for something. They are readily available based on fiberglas and aluminium, can be easily designed to whatever shape one likes, are manufactured precisely, allow to have holes and cut-outs, metal layers (even if you do not actually want to create circuits you can still have a metal layer under the soldermask to greatly improve the look of the latter), soldermask (what the surface usually is covered with) can be chosen as one of a number of different colors and the surface can be printed on as well with usually white or black print (that's called 'silkscreen' if you are curious). They are also relatively cheap on top of that. (I dread to think what an aluminium plate with an irregular shape and some cut-outs might cost if one ordered it at a regular metal-working shop.)

rkagerer 4y ago
I like the way BLOCKCLOCK mini makes the PCB part of the aesthetics and structure of their product: https://blockclockmini.com/ https://blockclockmini.com/
aaaaaaaaata 4y ago
> (I dread to think what an aluminium plate with an irregular shape and some cut-outs might cost if one ordered it at a regular metal-working shop.) Coming from the other side of this fence, I dread to think what alloy an electronics supplier would end up sending me instead of the metal that I asked for, and what surprises that might bring me structurally/chemically.
- R0b0t1 4y ago
  The materials used in PCB manufacture are normally specified exactly. Chemical compatibility still matters.
IshKebab 4y ago
Aluminium plate can be laser cut or water cut and if you're doing 2D stuff then it's simple enough that they can give you an online quote and there are some fairly cheap providers in China. Maybe not quite as cheap as OSHPark for very small parts, but you do get aluminium instead of fibreglass.
Karliss 4y ago
There are online laser/waterjet cutting services with relatively cheap prices. Just did quick experiment with online quote calculators for pcb and laser cut approaches. With somewhat default config and 5 50mmx150mm parts I got 35$ for PCB (1.6mm default thicknes) and 22€ for laser cut aluminium part (1.5mm). The difference was as soon as you moved away from default PCB params and tried to choose thicker aluminum price quickly skyrocketed 2mm->60$, 3mm -> 200$. Laser cutting service didn't care about what they cut too much, increasing thickness up to 6mm, price slowly raised to 30€. Cutting service also had the benefit of specifying what kind of aluminum alloy they will use and choosing between various surface finishes. On the other hand for PCB you get silkscreen at no additional cost. Looking at different metal cutting service they offered even cheaper price 2x5$ - 7x5$ (depending on thickness) for same parts and choice between different aluminum alloys.
- naikrovek 4y ago
  a lot of people get this wrong, and a lot of people aren't from the US, so for anyone that doesn't know, the dollar sign goes before the number, if you care about correctness. you say it after, but when written, it goes before.
dijonman2 4y ago
Marco Reps on YT uses PCBs as enclosure panel faces. It’s cost effective and delivers a nice finish. Highly recommend you check out his videos.

rkagerer 4y ago

I like the way BLOCKCLOCK mini makes the PCB part of the aesthetics and structure of their product: https://blockclockmini.com/ https://blockclockmini.com/

aaaaaaaaata 4y ago

> (I dread to think what an aluminium plate with an irregular shape and some cut-outs might cost if one ordered it at a regular metal-working shop.) Coming from the other side of this fence, I dread to think what alloy an electronics supplier would end up sending me instead of the metal that I asked for, and what surprises that might bring me structurally/chemically.

R0b0t1 4y ago
The materials used in PCB manufacture are normally specified exactly. Chemical compatibility still matters.

IshKebab 4y ago

Aluminium plate can be laser cut or water cut and if you're doing 2D stuff then it's simple enough that they can give you an online quote and there are some fairly cheap providers in China. Maybe not quite as cheap as OSHPark for very small parts, but you do get aluminium instead of fibreglass.

Karliss 4y ago

There are online laser/waterjet cutting services with relatively cheap prices. Just did quick experiment with online quote calculators for pcb and laser cut approaches. With somewhat default config and 5 50mmx150mm parts I got 35$ for PCB (1.6mm default thicknes) and 22€ for laser cut aluminium part (1.5mm). The difference was as soon as you moved away from default PCB params and tried to choose thicker aluminum price quickly skyrocketed 2mm->60$, 3mm -> 200$. Laser cutting service didn't care about what they cut too much, increasing thickness up to 6mm, price slowly raised to 30€. Cutting service also had the benefit of specifying what kind of aluminum alloy they will use and choosing between various surface finishes. On the other hand for PCB you get silkscreen at no additional cost. Looking at different metal cutting service they offered even cheaper price 2x5$ - 7x5$ (depending on thickness) for same parts and choice between different aluminum alloys.

naikrovek 4y ago
a lot of people get this wrong, and a lot of people aren't from the US, so for anyone that doesn't know, the dollar sign goes before the number, if you care about correctness. you say it after, but when written, it goes before.

dijonman2 4y ago

Marco Reps on YT uses PCBs as enclosure panel faces. It’s cost effective and delivers a nice finish. Highly recommend you check out his videos.