To design an enclosure for circuit board, let’s consider the PCB design process. The mechanical design of the PCB must be matched to the enclosure selected. So the enclosure DXF files must be imported into the PCB CAD layout software right at the start of the PCB layout process. The PCB layout is then generated around this mechanical drawing.
Performing both the PCB layout and the mechanical design at the same time achieves excellent dimensional accuracy. Mounting holes or spigots will line up. Connectors will fit through the enclosure. LEDs will line with associated apertures. Should the enclosure require any silk-screened graphics, this can be designed and aligned at the same time.
A stock enclosure will almost certainly need customising to your requirements. The enclosure suppliers may offer to machine do the machining for you. All engineering subcontractors will program their milling machines from DXF files which your PCB CAD layout software should be able to output. The photography for the silk-screening of the enclosure can be produced from Gerber or HPGL format files.
Whilst the enclosure company is machining and silk-screening the enclosures, the PCB can be manufactured at the same time. When the two come together they should fit perfectly.
With a little careful planning, very professional results can be produced at low cost, even for small runs.