PCBs are incredibly strong, and can be obtained for a very reasonable price. Based on published Raspberry Pi4 mechanical dimensions I decided to make a minimal enclosure for the Raspberry Pi 4. One version comes with a smooth top, the other features a prototyping area. The device was designed largely in KiCad, with purchased screws and standoffs.

One challenge was getting the bottom spacers correct, which I accomplished by cutting them out of clear acrylic on a laser cutter. I also cut out a small wrench to help with assembly, which is included with orders of this product on Tindie that include a hardware kit. DIN rail adapters are available as an option.

The top section was prototyped on this laser cutter, allowing me to correct a few very minor errors before ordering these from PCBWay. In part because of this process, things fit perfectly the first time. That being said, as seen in the KiCad screencap above, I have a few improvements on the base I'd like to make if I order another batch.

See one of these PCB enclosures being assembled, along with a bit of explanation, in the video below: