The longer answer is a bit more in-depth. Because we do not offer custom molds, mounting bosses cannot be molded directly into custom locations. Instead, we offer an easy solution, which can be far more cost-effective than ordering custom molds, particularly for shorter runs. This solution has three main steps:
Removing standard mounting bosses. Mounting bosses are built directly into the enclosure mold, and although the mold cannot be changed, the bosses can be removed. We can remove mounting bosses one of two ways, depending on the type of series being molded and customized. The bosses can be excluded during the molding process, or they can be machined out after molding, using CNC milling.
Applying countersunk holes to custom mounting boss locations. Once standard bosses have been removed, we machine countersunk holes into the new custom boss locations so that new bosses can be attached. This allows the customer to easily assemble new bosses in their required locations.
Assembling stand-offs to new boss locations. After we have supplied the plastic enclosures with custom boss holes, the customer purchases and assembles correctly-sized stand-offs which act as mounting bosses. Although we do not supply standoffs, we recommend Keystone Electronics (www.keyelco.com) as a supplier; #4-40 is the typical size for standoffs, but other sizes may be used as well. Customers can consult with a Polycase engineer to determine which standoffs will best fit the customized enclosure.