Industrial Designer / Mechanical Engineer — 3D-PrintSealed Enclosure 60 GHz mmWave Radar inwall unit

We need a sealed, 3D-printable enclosure for a 60–64 GHz mmWave radar sensor that retrofits into a standard single-gang low-voltage wall opening. The goal is a unit that disappears into the wall — it should read as a blank plate, not as a sensor. This is a tightly scoped job with a clear deliverable. We are not asking you to design a product line. We are asking you to design one part, correctly, with real RF constraints, and hand us files we can print this month. About the product: we build identity-first access control hardware — a door unit that recognises an approaching person and confirms they are a living human, using mmWave radar rather than cameras. The enclosure you design houses the radar. It is a real product heading into pilot deployments, not a concept exercise. What you're designing One sealed unit, roughly the footprint of a light switch plate, containing: A TI IWR6843ISK / IWR6843ISK-ODS radar module (exact dimensions supplied at kickoff) A 125 kHz LF RFID reader coil PoE cable entry — low voltage only, no mains RF absorber lining on the rear and side internal surfaces A flat replaceable radome disc cut from 1.59 mm (1/16") sheet stock The radome is not 3D printed and must not be. It is a flat disc of bought sheet material seated in a printed rebate and held by a printed retaining ring. Your design must make that disc swappable without destroying the unit. The constraints that actually matter These are non-negotiable and they are why we need someone who has done RF-adjacent mechanical work: Radome thickness is fixed at 1.59 mm and the material is a flat purchased sheet. Design the rebate and retaining ring around it. Antenna-to-radome air gap must be 4.84 mm, and must be adjustable at prototype stage via shim washers or stacked standoffs. No metal anywhere in the radar's forward cone. No metal fasteners, no metal trim ring, no metal mesh. Nylon or printed fasteners only in that zone. The aperture must flare, not tunnel. The ODS variant needs ±60° azimuth and elevation clearance. A flat plate recessed behind a straight-walled hole clips the field of view. Model the flare to the cone. A reference reflector boss at a fixed known standoff inside the housing, for self-calibration. We will specify the position; you model the feature and hold the tolerance. Thermal. The radar dissipates 2–2.5 W with no airflow inside a sealed wall cavity. We need a conduction path to the mounting bracket. Mounts to a standard low-voltage retrofit ring (Arlington LV1 or equivalent). The unit must pass through the ring opening during install. Deliverables Native CAD (Fusion 360 preferred, SolidWorks acceptable), fully parametric STEP and STL, print-ready, correctly oriented, with support strategy noted Two build variants sharing a common core: front-facing (ISK) and recessed wide-FOV (ISK-ODS) Assembly drawing and fastener BOM Two or three photoreal renders of the final design One revision round after we print and test-fit Terms NDA and IP assignment required before kickoff. All work product is ours on payment. To apply Don't send a generic proposal — we will not read it. Answer these four: Show us an enclosure you designed that houses an RF or sensing component. What was the constraint you had to design around? What's your read on printing the housing in FDM vs SLA for this application, and why? Have you worked to a specified antenna keep-out or radome stack before? Describe it. What's the first question you'd ask us before starting?