At Cullen 3D Design, we pride ourselves on our ability to provide bespoke solutions tailored to our clients’ unique requirements. Recently, we were approached with an intriguing challenge: designing a custom housing for a sensor that needed to be separated from the frame of a machine. The client required a secure, precise, and durable bracket that would seamlessly integrate with their existing setup. Here’s how we delivered beyond expectations.

The Challenge

The client presented us with a sensor that was previously mounted directly onto the machine’s frame. This setup posed several issues, including potential interference and vibrations affecting the sensor’s accuracy. The task was to design a housing that would isolate the sensor from the frame, ensuring optimal performance and reliability.

The Solution

Our team set to work, carefully analysing the specifications and constraints. We designed a robust bracket that could be easily fitted to the existing holes in the machine’s frame. Here’s a step-by-step overview of our process:

  1. Requirement Gathering: Understanding the precise dimensions and requirements for the housing.
  2. Concept Design: Creating initial sketches and 3D models to visualise the concept.
  3. Client Review: Collaborating with the client to refine the design based on their feedback.
  4. Final Design: Developing a detailed 3D model ready for printing.

Implementation and Results

Once the design was finalised, we proceeded to 3D print the part using high-quality materials to ensure durability and precision. The printed housing was then fitted onto the machine. The installation was straightforward, thanks to the precise alignment with the existing holes.

The client was delighted with the results. The new housing not only resolved the interference issues but also enhanced the overall reliability of the sensor. This project exemplifies our commitment to delivering ‘Design Beyond Limits’.


At Cullen 3D Design, we thrive on challenges and are dedicated to providing innovative solutions through custom 3D design and printing. If you have a project that requires a tailored approach, we’re here to help. Contact us today to find out how we can turn your ideas into reality.