Author Topic: Small project box for PCB with single DSub cutout??......  (Read 2277 times)

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Online SmokeyTopic starter

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Small project box for PCB with single DSub cutout??......
« on: June 23, 2026, 12:13:51 am »
I'm looking for a source of small project boxes with a single DSub cutout on one end.  Like a DSub clamshell, but instead of being for a cable, it's for a PCB assembly.  All connections into the thing are through the dsub so no need for a cable port at all.

I found this, which is really close:
https://www.winford.com/products/ecb9x.php



The size is about right, but that still has the cable port on the other end.  Not necessarily a show stopper in this case, but not ideal.
A small box with a panel with a single dsub cutout would also work.

thoughts?

::EDIT:: Sorry, details I forgot. 
Needs to house a PCB.
HDDsub with 3 rows.
Need a bunch of them for a production type thing (so no 3D printing).
« Last Edit: June 23, 2026, 01:24:27 am by Smokey »
 

Offline tooki

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Re: Small project box for PCB with single DSub cutout??......
« Reply #1 on: June 23, 2026, 12:52:27 am »
A gender changer backshell with a blind cover on one end?
 

Online squadchannel

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Re: Small project box for PCB with single DSub cutout??......
« Reply #2 on: June 23, 2026, 12:58:25 am »

DIY RS-232-to-USB adapter. I used a backshell.

3D printing is one option.
 

Online SmokeyTopic starter

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Re: Small project box for PCB with single DSub cutout??......
« Reply #3 on: June 23, 2026, 12:59:09 am »
A gender changer backshell with a blind cover on one end?

The way normal clamshells hook around the dsub doesn't work with a pcb I think.
 

Online SmokeyTopic starter

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Re: Small project box for PCB with single DSub cutout??......
« Reply #4 on: June 23, 2026, 01:00:10 am »
Unfortunately I need a hddsub with 3 rows so I can't center mount the board.
 

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Re: Small project box for PCB with single DSub cutout??......
« Reply #5 on: June 23, 2026, 02:10:38 am »
Unfortunately I need a hddsub with 3 rows so I can't center mount the board.
How is that relevant or matching to your opening post? Showing a case that it barely larger than the connector outline, just like a backshell of which some can fit a right angle through hole connector.

Or is this yet another thread of drip-fed requirements?
 
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Online SmokeyTopic starter

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Re: Small project box for PCB with single DSub cutout??......
« Reply #6 on: June 23, 2026, 03:16:24 am »
I was replying to squad channels photo of the board mounted down the middle of a normal dsub pin rows.  If you know how to do that with a 3rd row of pins where the board needs to go then I want to hear about it.
 

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Re: Small project box for PCB with single DSub cutout??......
« Reply #7 on: June 23, 2026, 03:50:36 am »
Unfortunately I need a hddsub with 3 rows so I can't center mount the board.
How is that relevant or matching to your opening post? Showing a case that it barely larger than the connector outline, just like a backshell of which some can fit a right angle through hole connector.

Or is this yet another thread of drip-fed requirements?
I was replying to squad channels photo of the board mounted down the middle of a normal dsub pin rows.  If you know how to do that with a 3rd row of pins where the board needs to go then I want to hear about it.
What is forcing you to mount the board in that way?
Why is a backshell not a solution?
 

Online SmokeyTopic starter

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Re: Small project box for PCB with single DSub cutout??......
« Reply #8 on: June 23, 2026, 04:26:56 am »
??  I think this is just a failure to communicate.

I have a normal pcb, with a normal through hole right angle hddsub. 
 

Offline tooki

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Re: Small project box for PCB with single DSub cutout??......
« Reply #9 on: June 23, 2026, 01:09:50 pm »
A gender changer backshell with a blind cover on one end?

The way normal clamshells hook around the dsub doesn't work with a pcb I think.
It might for some designs of gender changer backshells.

I was replying to squad channels photo of the board mounted down the middle of a normal dsub pin rows.  If you know how to do that with a 3rd row of pins where the board needs to go then I want to hear about it.
You could theoretically use two 1.2mm thick PCBs, plus some header to connect the two boards. One board would be between, say, rows 2 and 3, soldered to both, while the other sits between rows 1 and 2, but is soldered only to row 1.

Need a bunch of them for a production type thing (so no 3D printing).
Maybe it’s worth revisiting 3D printing. Not all 3D printing technologies look like crap.

Or could you use an extruded aluminum enclosure with the d-sub screwed to the end panel?



How many units are we talking here?

What size connector? We know it’s d-sub HD, but as you know, the 15, 26, 44, 62, and 78-pin versions have different widths…

How will it be used? Does it need to have thumbscrews to screw directly onto some device’s d-sub port? Or could it be used with a cable?

Or is this yet another thread of drip-fed requirements?
Indeed. Smokey, please provide all the requirements now, all at once.
 

Online SmokeyTopic starter

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Re: Small project box for PCB with single DSub cutout??......
« Reply #10 on: June 23, 2026, 09:42:43 pm »
Just to clarify, this isn't anther thread claiming to be a hobbyist who's SUPER EXCITED ABOUT DSUB ENCLOSURES!!!!11111.1....... PLEASE HELP RIGHT NOW!!!!.... I haven't spent the last 10 years working on an RC filter board (which for whatever reason still isn't working) and I'm not hacking together one board for my own personal use and demanding that it uses aerospace qualified parts... I'm also not building a one man show mars rover for mars out of power wheels parts......

I'm in the early stages of designing an actual thing and I'm looking into if there is a viable off the shelf DSub housing solution BEFORE I fully specify every one of the design details.  I'm only looking at HDDSub first because of the possibility that there is an off the shelf housing for a small DSub board considering the widespread usage of DSub for many many years.  If it turns out there isn't a great solution around this, then I'll pivot and look for other connector/housing options.  I didn't overly constrain the spec because there are some things I can work around if there is a viable housing option.  Like I can use a HDDSub15 as a minimum, but I can also use a HDDSub26 if that housing exists but the 15 doesn't.  Ultimately it would be great if we ended up selling these things in the 1000s, but I can't commit to an injection mold for this project because of the unknown sales and ramp rate right now.  3D printing is not really viable apart from prototyping. 

So I hope that clarifies a bit.
« Last Edit: June 23, 2026, 09:44:18 pm by Smokey »
 

Offline langwadt

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Re: Small project box for PCB with single DSub cutout??......
« Reply #11 on: June 23, 2026, 10:06:33 pm »
why no 3d print? resin prints are getting pretty damn good

or just mill two shells out of some thick plastic plate
 

Online SmokeyTopic starter

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Re: Small project box for PCB with single DSub cutout??......
« Reply #12 on: June 23, 2026, 10:21:20 pm »
why no 3d print? resin prints are getting pretty damn good
or just mill two shells out of some thick plastic plate

Milling is out because I may (and hopefully will) need a lot of housings and that would be the worst of all worlds, slow and expensive (and unnecessary in that milling gains me almost nothing at huge downsides). 
3D printing would probably be marginally acceptable at first, but would suck in the transition period between low volume sales and high enough volume sales to warrant an injection mold.  Also I really don't want to have to babysit my own 3D print farm (especially resin) and outsourcing pushes cost further into the injection mold territory than I can commit to right now.  It's less about looking like crap and more about cost, lead times, and/or machine operation hassle.

An inexpensive off the shelf solution is likely ideal for the quantities I expect this thing to do.  So that's why I'm investigating that up front, and why as I said I'm willing to design the thing around an OTS housing that is close.
« Last Edit: June 23, 2026, 10:27:44 pm by Smokey »
 

Offline tooki

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Re: Small project box for PCB with single DSub cutout??......
« Reply #13 on: June 24, 2026, 03:19:57 pm »
Just to clarify, this isn't anther thread claiming to be a hobbyist who's SUPER EXCITED ABOUT DSUB ENCLOSURES!!!!11111.1....... PLEASE HELP RIGHT NOW!!!!.... I haven't spent the last 10 years working on an RC filter board (which for whatever reason still isn't working) and I'm not hacking together one board for my own personal use and demanding that it uses aerospace qualified parts... I'm also not building a one man show mars rover for mars out of power wheels parts......
What the hell, dude? Nobody had insinuated anything of the sort. We‘re trying to help you, because it’s an interesting question, but you’re doing everything in your power to make it hard for us to help you!

I'm in the early stages of designing an actual thing and I'm looking into if there is a viable off the shelf DSub housing solution BEFORE I fully specify every one of the design details.  I'm only looking at HDDSub first because of the possibility that there is an off the shelf housing for a small DSub board considering the widespread usage of DSub for many many years.  If it turns out there isn't a great solution around this, then I'll pivot and look for other connector/housing options.  I didn't overly constrain the spec because there are some things I can work around if there is a viable housing option.  Like I can use a HDDSub15 as a minimum, but I can also use a HDDSub26 if that housing exists but the 15 doesn't.  Ultimately it would be great if we ended up selling these things in the 1000s, but I can't commit to an injection mold for this project because of the unknown sales and ramp rate right now.  3D printing is not really viable apart from prototyping. 

So I hope that clarifies a bit.
So you don’t actually need to mate to a specific connector? Typically, tiny d-sub enclosures (like the ones used for d-sub software dongles) were intended to mount directly onto another device. (For example, a software dongle going straight onto a PC’s parallel port.) And that requirement, in turn, places severe dimensional limitations on the enclosure.

Since you refused to answer my question about that, I can only infer from the last reply that you have connector flexibility, in which case, you’re not mating directly onto a device’s port. Is that correct? If so, then just use a small enclosure of your choice from Hammond and use their customization service for the port opening and any printing you want. Their minimum order for customization is just 25 pieces.

Could you please see my previous reply, and explicitly and carefully answer each and every one of my questions, and then explain more about your product?

P.S. I guess you didn’t do any homework on d-sub connectors, because a DB-15 and HD-26 are the same size. 
 

Online SmokeyTopic starter

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Re: Small project box for PCB with single DSub cutout??......
« Reply #14 on: June 24, 2026, 09:53:39 pm »
Just to clarify, this isn't anther thread claiming to be a hobbyist who's SUPER EXCITED ABOUT DSUB ENCLOSURES!!!!11111.1....... PLEASE HELP RIGHT NOW!!!!.... I haven't spent the last 10 years working on an RC filter board (which for whatever reason still isn't working) and I'm not hacking together one board for my own personal use and demanding that it uses aerospace qualified parts... I'm also not building a one man show mars rover for mars out of power wheels parts......
What the hell, dude? Nobody had insinuated anything of the sort. We‘re trying to help you, because it’s an interesting question, but you’re doing everything in your power to make it hard for us to help you!

I'm in the early stages of designing an actual thing and I'm looking into if there is a viable off the shelf DSub housing solution BEFORE I fully specify every one of the design details.  I'm only looking at HDDSub first because of the possibility that there is an off the shelf housing for a small DSub board considering the widespread usage of DSub for many many years.  If it turns out there isn't a great solution around this, then I'll pivot and look for other connector/housing options.  I didn't overly constrain the spec because there are some things I can work around if there is a viable housing option.  Like I can use a HDDSub15 as a minimum, but I can also use a HDDSub26 if that housing exists but the 15 doesn't.  Ultimately it would be great if we ended up selling these things in the 1000s, but I can't commit to an injection mold for this project because of the unknown sales and ramp rate right now.  3D printing is not really viable apart from prototyping. 

So I hope that clarifies a bit.
So you don’t actually need to mate to a specific connector? Typically, tiny d-sub enclosures (like the ones used for d-sub software dongles) were intended to mount directly onto another device. (For example, a software dongle going straight onto a PC’s parallel port.) And that requirement, in turn, places severe dimensional limitations on the enclosure.

Since you refused to answer my question about that, I can only infer from the last reply that you have connector flexibility, in which case, you’re not mating directly onto a device’s port. Is that correct? If so, then just use a small enclosure of your choice from Hammond and use their customization service for the port opening and any printing you want. Their minimum order for customization is just 25 pieces.

Could you please see my previous reply, and explicitly and carefully answer each and every one of my questions, and then explain more about your product?

P.S. I guess you didn’t do any homework on d-sub connectors, because a DB-15 and HD-26 are the same size.

Actually, by not over constraining the problem with imaginary requirements that don't yet exist I'm allowing more potential solutions. 

I not only don't have to connect to a specific DSub connector on a specific piece of equipment, I don't have any specific connector requirements at all right now.  If you had read my post which you just quoted, that would have been very clear.  Any requirements you think I have that I didn't specifically state you made up on your own.

Again, if you read my post, which you obviously didn't, then you would see that I specially only talk about HDDSub.  I point out that HDDSub15 and HDDSub26 are both viable (again because I don't have an actual connector requirement) and those are indeed different sizes.  I've been making products with HDDsub for decades at this point, so ya....

The answers should be obvious based on what I've already said but here, so you don't need to read anything else I already posted...
How many units are we talking here?
       25-50 piece batches for the foreseeable future. Hopefully 1000s eventually.  Timeline unknown.

What size connector? We know it’s d-sub HD, but as you know, the 15, 26, 44, 62, and 78-pin versions have different widths…
       15pin minimum, so HDDsub15 +.  Probably not bigger than 26, but if the right housing showed up at the right price I could see what it would look like with more pins.  And I specifically mentioned HDDsub15 and HDDsub26, so ya...

How will it be used? Does it need to have thumbscrews to screw directly onto some device’s d-sub port? Or could it be used with a cable?
       I don't have any specific requirements, again.  So board-to-board?  Sure.  Wire-to-board?  Ya, it will likely be wire-to-board but you can also plug a wire-to-board connector into a board-to-board configuration, so sure.  Does a DSub stick out the end of an OTS housing that doesn't require me to modify anything?  Cool, then I'll take a look and see if it will work.  Just so I've fully answered all your specific questions so I've satisfied your demands and you don't need to infer anything... Thumb screws?  Sure, should work.  No Thumbscrews?  Sure, should work. 

If you look at my initial question/request it actually relies on having zero information about the application.  I'll restate it here:
     I'm looking for a small off-the-shelf enclosure with a single D-Sub cutout/port that can take a board-mounted DSub.

« Last Edit: June 24, 2026, 11:22:21 pm by Smokey »
 

Online sleemanj

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Re: Small project box for PCB with single DSub cutout??......
« Reply #15 on: June 24, 2026, 11:00:41 pm »
FDM 3D printers are very fast these days.  I wouldn't discount them for small-medium production volumes of a small part like this.  Probably get at least 10 pairs on a print bed at a time.

Otherwise, I'd use an enclosure with a slide-out front plate, then get said plate manufactured as a PCB.  Plenty of such enclosures on Aliex etcetera.





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Online SmokeyTopic starter

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Re: Small project box for PCB with single DSub cutout??......
« Reply #16 on: June 24, 2026, 11:03:21 pm »
Actually, taking another look at squadchannel's photo, I didn't initially see he used the cable port on the other end of the clamshell as a USB jack.  That is pretty slick, and gives the hole some purpose apart from just being a hole for nothing.  My thing doesn't need USB, but that might be a good excuse to have a port... Hmm.. now I need to look for a clamshell that works with a PCB.
 

Offline langwadt

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Re: Small project box for PCB with single DSub cutout??......
« Reply #17 on: June 24, 2026, 11:12:08 pm »
FDM 3D printers are very fast these days.  I wouldn't discount them for small-medium production volumes of a small part like this.  Probably get at least 10 pairs on a print bed at a time.

resin looks nicer and it'll take the same time no matter how many you fit at once
 

Online SmokeyTopic starter

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Re: Small project box for PCB with single DSub cutout??......
« Reply #18 on: June 24, 2026, 11:32:28 pm »
FDM 3D printers are very fast these days.  I wouldn't discount them for small-medium production volumes of a small part like this.  Probably get at least 10 pairs on a print bed at a time.

resin looks nicer and it'll take the same time no matter how many you fit at once

+ Wash, + Cure, + tank maintenance :(
 

Offline tooki

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Re: Small project box for PCB with single DSub cutout??......
« Reply #19 on: June 25, 2026, 02:09:06 pm »
Actually, by not over constraining the problem with imaginary requirements that don't yet exist I'm allowing more potential solutions. 
Good product design arises from good requirements engineering. The entire point of design is to narrow things down until the ideal solution emerges.

Since you’ve rescinded the requirements in the opening post, then you are basically saying that you have practically zero constraints of any kind, other than “not 3D printed”. It could be any connector of any kind, with any pin count, at any price point, in any kind of “small” enclosure, of any material.

How do you expect anyone to make useful recommendations when the problem space is basically infinite?


In such a situation, when you’re asking people for help, it’s best to tell them what you want to do, not how you want to do it. You came in with a very narrow requirement (a d-sub enclosure for a PCB, with no cable exit) that suggests an exotic application. But the more we probe, the more we discover that there is no need for this narrow requirement, so we are trying to find out what your actual requirements are — even the requirements and assumptions you have in your mind without realizing it.

I not only don't have to connect to a specific DSub connector on a specific piece of equipment, I don't have any specific connector requirements at all right now.  If you had read my post which you just quoted, that would have been very clear.  Any requirements you think I have that I didn't specifically state you made up on your own.
I read your post thoroughly.

Not “making up”, but inferring logically from what you have provided. See the point above about your initial narrow requirement.

Again, if you read my post, which you obviously didn't, then you would see that I specially only talk about HDDSub.  I point out that HDDSub15 and HDDSub26 are both viable (again because I don't have an actual connector requirement) and those are indeed different sizes.  I've been making products with HDDsub for decades at this point, so ya....
I did read your post thoroughly.

You have waffled between d-sub and d-sub hd throughout the thread. Regardless, my point was that d-sub and d-sub hd shells are the same size (just not at the same pin count, obviously): you questioned whether an HD-15 enclosure exists, but obviously they do, since DB-9 enclosures exist.

Someone who’s worked with d-sub hd for decades should know this by now, no?

What size connector? We know it’s d-sub HD, but as you know, the 15, 26, 44, 62, and 78-pin versions have different widths…
       15pin minimum, so HDDsub15 +.  Probably not bigger than 26, but if the right housing showed up at the right price I could see what it would look like with more pins.  And I specifically mentioned HDDsub15 and HDDsub26, so ya...
Does it have to be d-sub hd? If you could use non-hd d-sub, you could then use an off-the-shelf backshell and solder the PCB between the rows. There are manufacturers that make blind plugs for the cable holes in their backshells.

How will it be used? Does it need to have thumbscrews to screw directly onto some device’s d-sub port? Or could it be used with a cable?
       I don't have any specific requirements, again.  So board-to-board?  Sure.  Wire-to-board?  Ya, it will likely be wire-to-board but you can also plug a wire-to-board connector into a board-to-board configuration, so sure.  Does a DSub stick out the end of an OTS housing that doesn't require me to modify anything?  Cool, then I'll take a look and see if it will work.  Just so I've fully answered all your specific questions so I've satisfied your demands and you don't need to infer anything... Thumb screws?  Sure, should work.  No Thumbscrews?  Sure, should work.
Then you need to think about your application more and determine what situations matter and which don’t. Because no, a wire-to-board connector may not work as board-to-board if the enclosure mechanically interferes.

If you look at my initial question/request it actually relies on having zero information about the application.  I'll restate it here:
     I'm looking for a small off-the-shelf enclosure with a single D-Sub cutout/port that can take a board-mounted DSub.
Your initial post certainly does not state that you have zero information about the application.

And you need to understand what I am telling you: getting useful responses from people relies on them having information about the application. What you’re doing now is just gratuitous wasting of others’ time, of the very worst kind: asking essentially open-ended questions and then barking at people when they ask for additional information.
 

Offline spostma

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Re: Small project box for PCB with single DSub cutout??......
« Reply #20 on: June 25, 2026, 02:30:03 pm »
An image search of your Winford connector hood on Aliexpress shows a similar box
that should be compatible with a 3-row VGA style connector:
https://www.aliexpress.com/item/32879710103.html
 
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Online SmokeyTopic starter

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Re: Small project box for PCB with single DSub cutout??......
« Reply #21 on: June 25, 2026, 10:05:47 pm »
...
And you need to understand what I am telling you: getting useful responses from people relies on them having information about the application. What you’re doing now is just gratuitous wasting of others’ time, of the very worst kind: asking essentially open-ended questions and then barking at people when they ask for additional information.

Cool.  I think we've pretty much covered everything.

As I like to tell my mom sometimes...  Thank you very much for all your "feedback".  You have been very "helpful".  I really appreciate all your "helpful" "feedback". 

If my lack of expertness is making you this crazy, maybe it's time to move on and "help" some other not-an-experts learn the "right way" to design stuff..
« Last Edit: June 25, 2026, 10:18:28 pm by Smokey »
 

Online SmokeyTopic starter

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Re: Small project box for PCB with single DSub cutout??......
« Reply #22 on: June 25, 2026, 10:16:32 pm »
An image search of your Winford connector hood on Aliexpress shows a similar box
that should be compatible with a 3-row VGA style connector:
https://www.aliexpress.com/item/32879710103.html

Cool.  Getting warmer.  Ya snap together is nice.  It's unfortunate they never have mechanical drawings.  Makes it hard to determine if there is enough room and what shape to make the board outline for something like that.

Now starts the always fun adventure of chatting with alibaba sellers..
« Last Edit: June 25, 2026, 10:59:10 pm by Smokey »
 

Offline spostma

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Re: Small project box for PCB with single DSub cutout??......
« Reply #23 on: June 26, 2026, 07:21:58 am »
well, I might have an even better option for you:
https://www.pactecenclosures.com/product-category/connector/

And probably the best one for you;
both for DB-9 or HD-15 right angle connectors,
and even in three enclosure size variants:
https://www.pactecenclosures.com/product/cns-0004/

I attached the drawing for you.
 
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Online SmokeyTopic starter

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Re: Small project box for PCB with single DSub cutout??......
« Reply #24 on: June 26, 2026, 07:38:08 am »
well, I might have an even better option for you:
https://www.pactecenclosures.com/product-category/connector/

And probably the best one for you;
both for DB-9 or HD-15 right angle connectors,
and even in three enclosure size variants:
https://www.pactecenclosures.com/product/cns-0004/

I attached the drawing for you.

Hell ya.  That's the thing.  And $2.71 in 1s.  You are officially my new personal hero. 
 


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