I agree. The problem is trying to do this at scale. I don't want to do it myself as it would be too time consuming and messy.
Without having the funds for injection/pressure molding, I haven't been able to find a good solution. Maybe there are cost effective services that would work like PCB potting or overmolding.
One service that I found that looks promising is Cavist:
Here's an option. There are companies in China which sell standard enclosures for USB plug-in devices. They'll even throw in a color of your choice and a sticker. You'd have to redesign your board to fit their case, but that may be a lot easier than dealing with encapsulation.[1]
The problem is that the U2F specification requires users to approve authentication requests by pressing a button and none of the existing enclosures have a space for one. Entirely coincidentally, the company behind it (Yubico) already had a design with a button because their original second-factor proposal had no other way of knowing you want to authenticate. It's a little pointless on U2F but the spec requires it.
board respin required...either position the button so you squeeze the enclosure to press the button (it flexes a bit), or drill a small hole (use a jig to get the drill bit in the right location
enclosure co's will also customize/drill holes for you but its probably easier for you to just diy!
Oh, nice solution. I thought he'd have to order USB device enclosures from China, but these are from Bud Industries in Ohio, the classic maker of electronic enclosures for 80 years, and orderable from Digi-Key. (That means the parts will be good quality and they will show up on time.) Get a custom sticker printed, and you'll have a good MVP.
Good idea, but I see ads in that sector saying "Molds start at $4990".
I've seen people do things like this at TechShop. They carve a positive mold out of maybe a dense wood. Then use that to make an negative mold out of some pourable plastic like RTV. Then insert the device, pour in epoxy, and wait for it to cure. The negative molds wear out fast, but you can make more from the positives. There are lots of plastic options and books on this stuff. People use these processes to turn out stuff to sell on Etsy. All this is do-able, but usually messy.
Still, struggling through the process to have an MVP to show resellers is worth the trouble. If you get a big order, you can go out to Cavist or someone like them and have them produce in volume.
One super cheap idea that might be worth considering: clear shrink tubing. You could put whole trays of them at a time in your oven, just make sure the tubing is the right length and lined up right.
You might even be able to get away with not cutting out a hole for the button, as it could be activated through the flexible tubing.
Look for someone who's already encapsulated USB devices. They might be able to reuse an existing mold. That business is all tooling cost; per-unit cost is tiny.
But don't send the job to China, or your device will be copied, cheaper.
Honestly I think you're fine right now. Think of this initial run as a market test. If you end up selling out your entire stock, tell friends and family that you need a small loan and work with someone domestic to get your enclosure done.
Polycase might be a good place to start once you sell out. They sell generic cases and will quote you on modifications to their existing USB case.
After that (if you continue to sell out), you're probably a real business. Keep the domestic machine running and hop over to China to explore driving costs down. Probably explore what type of software/service might complement your hardware to drive recurring revenue. Create custom single unit packaging and bulk delivery packaging for consumer selling and business selling.
+1 on the case being a must have. I'll put some shrink tube over the ones I just ordered to keep them from getting banged up. Looking forward to trying it out in a few days.
Without having the funds for injection/pressure molding, I haven't been able to find a good solution. Maybe there are cost effective services that would work like PCB potting or overmolding.
One service that I found that looks promising is Cavist:
http://cavist.com/
But I haven't gone down this route or found someone that has. I might do this later on.