I am wary about the electrostatic ambient. I plan to place a few nanos and sensors, maybe with the batteries inside the case, as opposed to connected by cable, in a portable setting where they WILL be subjected to frictions and crushing pressures. 3D is out of the question at this moment. I only have an easily melt plastic which is not so easily molded and may actually produce some frictional electrostatic charge, though it accepts nail lacque quite well. I am thinking of using one of those clays that go hard on air or by drying, but I do not discard the possibility of using a clay that can be cooked into ceramic. Cardboard would also be VERY convenient because once I have a working design I can quickly make as many as I want, I can waterproof it with duct tape or similar and I can use more than one layer to add cushioning, besides being easy to replace, but I am not sure it would not affect the circuitry if it collapses and is pressed on it. Though I dislike the idea I am considering sinking the circuitry into the material and solidarize it rather than leaving air cushions, but again I fear the circuit would stop working immediately for these materials. Heat would be an additional consideration in such scenario, while for clays I see danger in working the case over the board, particularly for wet clays, because it may become smeared or stick to the board while working the case out. One other possibility is papier mache, which I know becomes very hard and sturdy, but it takes a while wet before drying, would have to be a closed, non articulated case and a real pain to make more than one. Finally neoprene would be a nice option because it provides cushioning in itself and cuts easily like cardboard, but heat may mount inside and it is easier to find dressed in charge inducing polyester than alone; I also fear it may drive circuits crazy if in direct contact. Wood is not an option for these project, too much workmanship needed. Oh! foams would be nice too but much more complex to prepare compared to moldable clays, so they are out of the question here! It is not a matter of mass producing, but I will definitely need more than two gadgets, so metal is not the case either!
Cardboard and crushing pressures are not a good combination. I also don't think neoprene is appropriate. It may provide cushioning but you are better off to use a case that is strong enough to withstand the pressure.
What's your reason for not using a standard plastic or aluminum enclosure? You can buy them very cheaply on eBay or Aliexpress in a wide variety of dimensions.
Form
pert:
What's your reason for not using a standard plastic or aluminum enclosure?
Thought it was obvious. Form, size, fitness... These materials can be easily given form and made to fit better my purpose. For metal boxes I can use assorted candy boxes, have already done but you get what you find and that s it.
I ve found that if your gadget has standard push or sliding on/off buttons, you will find it on at some time if you place it off in a bag or a pocket and walk a little bit! This is happening with a power bank right now, the corner button is so soft it is always on no matter how I place it, one lighter would be so dangerous if it turns on by itself in my pocket I carry it empty, even the laptop has shown up on and superheated and I do carry it very carefully upright and padded! I can avoid this problem for my gadget if I make the case, of course.
The clay would be cool. There is polymer clay like Fimo that you bake in the oven to harden. Even cooler would be pottery but of course you need access to the equipment and it takes time to get it bone dry before you can fire. Be aware that it will shrink during baking/firing.
Well well well... NOW, I have my own reply: it does not matter at all, use KAPTON tape for the insulation. That s all, can insulate the circuit no space consumed and wrap it in any material you like. My polymer clay shrank but it makes great softy looking animated gadgets.