ZUMspot Case Blog

At ZUM Radio, we believe that great design doesn't just end with what's inside a product. The Elite 3.5 LCD ZUMspot's custom injection molded case was designed to be the sleekest, lightweight, and durable case on the market. Many hams are already familiar with our cases, but what they don't know is the behind-the-scenes process of converting an innovative idea into a reality. In this blog post, we will take you step-by-step through the process to give you an inside look into how our ZUMspot case became what it is today.

Current Elite 3.5 LCD ZUMspot case

Early design: In 2019, our team started the development of a new case to replace the previous acrylic design. Our goals were to maximize the efficiency of the assembling process, and to switch to a more cost-effective polycarbonate material. These changes would allow us to cut down on costs while increasing the sturdiness of the case material. Additionally, we wanted to design a case that would allow the user to see what’s inside their device. This is especially important for our customers who are interested in seeing the ZUMspot’s inner layout. 

Then, in 2021, we redesigned the case once more to fit the Pi 4 board upgrade. In order to achieve this, we again used CAD tools (Fusion 360) to help us design early concept cases. The image below is an example of how we used the software to complete this process.

ZUMspot design in Fusion 360 software

Prototypes: After outlining our initial designs, we 3D printed each model to test their functionality and aesthetic value. The image below shows one of our printed cases with an early vent/fan system. The fan cutouts looked nice but ended up being one of the most significant design alterations since it didn’t allow for proper airflow. Three large semi-circular slots were substituted so that they align perfectly with the fan airflow. Another major design alteration is the change in board fit. Since the Pi 4 board has different connectors/positions we had to change many things in the design.

3D printed model with previous diagonal air slot design

Manufacturing: With our final design ready, we finally purchased the plastic injection mold that was is used by our manufacturer to produce each of the pieces. Part of the manufacturing process can be seen in the video clip below, where two factory workers create a single ZUMspot case. Before the part is made, the workers have to add the threaded inserts into the mold and adjust the ejector pins. Once they’re done, all of the parts are inspected before they are ready to be used during final assembly. 

ZUMspot case in production

Factory workers add threaded inserts into the ZUMspot mold and adjust the ejector pins