EtherDirect Ideas

A running list of product, design and go-to-market ideas for EtherDirect, each with a verdict and next step.

Last updated: 2026-10-01 11:25 PDT · 1 idea(s)

IDIdeaAreaStatus
IDEA-001IronKey-style anodized aluminum shell for the dongleEnclosure / industrial designPromising: prototype with an off-the-shelf box
IDEA-001 · Enclosure / industrial design · 2026-10-01

IronKey-style anodized aluminum shell for the dongle

Promising: prototype with an off-the-shelf box
Concept render (AI-generated, not a real product): EtherDirect in a blue anodized aluminum extrusion with black end caps, an RJ45 on one end and USB-C on the other
Concept render (AI-generated, not a real product): EtherDirect in a blue anodized aluminum extrusion with black end caps, an RJ45 on one end and USB-C on the other Generated with Gemini image model
The inspiration: Kingston IronKey Keypad 200, metallic-blue anodized aluminum body with black plastic ends
The inspiration: Kingston IronKey Keypad 200, metallic-blue anodized aluminum body with black plastic ends Photo: basic-tutorials.com
Off-the-shelf option for prototyping: Hammond 1455 extruded aluminum enclosure (blue)
Off-the-shelf option for prototyping: Hammond 1455 extruded aluminum enclosure (blue) Photo: Hammond Manufacturing
Hammond 1455 with end bezels, the same extrusion + end-cap construction
Hammond 1455 with end bezels, the same extrusion + end-cap construction Photo: Hammond Manufacturing

Inspiration: Kingston IronKey Keypad 200: a metallic-blue anodized aluminum body, black plastic end caps, epoxy-potted electronics, IP57/IP68 with the cap on.

Verdict: Use the material and construction, not the IronKey shell itself. The IronKey is about 10 mm thick, and an RJ45 jack alone is about 13.5 mm tall, so EtherDirect needs its own profile of roughly 18-20 mm.

Why it works

  • Free heatsink: the MCU and Ethernet PHY run warm, and aluminum spreads the heat
  • EMI shielding helps with FCC/CE if the shell is grounded to the USB-C/RJ45 shield (anodize insulates, so you need masked contact points or a spring finger)
  • Looks and feels industrial and premium, like higher-end USB-Ethernet adapters
  • Cheap at volume: an extruded profile cut to length, anodized in any color, plus two molded end caps. Die roughly low-$k, parts roughly $1-3 each

Watch-outs

  • Ethernet 1500 V isolation: keep the magnetics clearance away from the metal, and don't count on the anodize as insulation
  • No Wi-Fi through metal: a wireless variant needs a plastic window or an end-cap antenna
  • Epoxy potting (the IronKey trick) gives tamper-evidence but kills rework and traps heat. Use conformal coating now, and potting later if security becomes a selling point

Next step: Find an off-the-shelf extruded aluminum enclosure (e.g. Hammond 1455 series) closest to the current board, and test fit, thermals and look before committing to a custom extrusion die.

Sources: Kingston IronKey Keypad 200 datasheet · Keypad 200 review (aluminum housing, plastic ends) · Hammond 1455 extruded aluminum enclosures

WhatsApp summary

💡 *EtherDirect Ideas*
• IDEA-001: IronKey-style anodized aluminum shell for the dongle → Promising: prototype with an off-the-shelf box
https://artifact.sahirm.com/a/etherdirect-ideas/