Custom Device Shell Design
3D-printed enclosures designed for discretion, blending seamlessly into any environment
Discreet Hardware for Real-World Operations
In red team operations and physical penetration testing, the ability to deploy devices without detection is critical. Standard enclosures can be conspicuous and raise suspicion. Our custom shell design service creates 3D-printed enclosures that transform your penetration testing devices into everyday objects that blend seamlessly into target environments.
We combine industrial design expertise with practical penetration testing experience to create shells that are not only visually appropriate but also maintain full device functionality, proper cooling, antenna placement, and access to ports and indicators.
Why Custom Shells Matter
A $3,000 penetration testing device is worthless if it's immediately discovered. Custom shells designed for specific environments dramatically increase operational success rates by:
- Reducing visual suspicion from security personnel and employees
- Matching environmental aesthetics (office, industrial, healthcare, etc.)
- Appearing as authorized, expected equipment
- Enabling longer-duration deployments without detection
Compatible with All Our Devices
Custom shells designed for any device in our lineup
USB Drive Module
Disguise as branded USB drives, phone chargers, conference badges, or other innocuous USB devices common in your target environment.
Keyboard Module
Hide keyboard pass-through devices in cable management boxes, desk organizers, or equipment-specific housings that blend with workstation setups.
Network Module
Design shells resembling network equipment, power strips, surge protectors, or environmental sensors appropriate for network closets and server rooms.
Long Distance Module
Create enclosures that look like building equipment, junction boxes, or utility infrastructure for outdoor or industrial deployments.
Command Module
Portable shells designed as briefcases, equipment cases, or backpack inserts for mobile command and control operations.
Custom Devices
For our custom-designed hardware, we create bespoke enclosures tailored to the device's specific form factor and deployment environment.
Shell Design Examples
Sample designs we've created for different environments and use cases
Phone Charger Shell
Device: USB Drive Module
Environment: Office/Corporate
Standard white phone charger design with USB-A and USB-C ports. Completely functional as a charger while device operates covertly. Common sight on desks and in conference rooms.
- ✓ Fully functional charging capability
- ✓ Standard wall plug form factor
- ✓ Internal antenna placement
- ✓ LED indicators hidden in design
Power Strip Shell
Device: Network Module
Environment: Server Rooms/IDF Closets
Functional power strip with integrated network tap device. Ethernet pass-through appears as standard surge-protected outlet strip. Blends perfectly in network closets and under-desk cable management.
- ✓ Working power outlets
- ✓ Network pass-through design
- ✓ Rack-mountable option available
- ✓ PoE-powered or AC operation
Equipment Junction Box
Device: Long Distance Module
Environment: Industrial/Manufacturing
Industrial-grade junction box design matching facility equipment. Appears as building infrastructure or utility equipment. Ruggedized for harsh environments with weatherproof sealing.
- ✓ IP65 weatherproof rating
- ✓ Standard industrial gray finish
- ✓ Mounting bracket included
- ✓ Cable gland ports
Conference Badge Holder
Device: USB Drive Module
Environment: Conferences/Events
Lanyard badge holder with integrated USB device. Appears as event credential while monitoring nearby conversations or providing covert network access. Perfect for social engineering scenarios.
- ✓ Standard badge holder size
- ✓ Lanyard attachment point
- ✓ Customizable branding
- ✓ Battery-powered operation
Network Equipment Shell
Device: Network Module
Environment: Data Centers
Professional rack-mountable enclosure resembling network switches or patch panels. Includes proper ventilation, LED indicators, and labeling provisions. Blends seamlessly in rack environments.
- ✓ 1U or 2U rack mount
- ✓ Standard 19-inch width
- ✓ Front panel Ethernet ports
- ✓ Matches Cisco/HP aesthetics
Medical Equipment Shell
Device: Custom Device
Environment: Healthcare
Enclosure designed to resemble medical monitoring or diagnostic equipment. Clean medical-grade plastic finish with appropriate labeling and compliance markings. Designed for hospital environments.
- ✓ Medical-grade ABS plastic
- ✓ Smooth, cleanable surfaces
- ✓ Appropriate safety markings
- ✓ Wall or cart mounting options
Our Design Process
From concept to 3D-printed prototype in 2-3 weeks
Requirements Gathering
We work with you to understand the target environment, deployment scenario, and operational requirements. We'll discuss what the device should resemble, size constraints, mounting requirements, and any specific features needed.
Duration: 1-2 days
Concept Design
Our designers create initial concept sketches and 3D models. We'll provide multiple design options showing different approaches to the shell design, including dimensions, material recommendations, and aesthetic variations.
Duration: 3-5 days
Client Review & Revision
You review the concepts and provide feedback. We'll refine the design based on your input, adjusting aesthetics, dimensions, or functional elements. We typically go through 1-2 revision cycles.
Duration: 2-3 days
Technical Engineering
We finalize the technical aspects: internal component layout, mounting points, port cutouts, ventilation, antenna placement, and cable routing. We ensure the design maintains device functionality while achieving the desired appearance.
Duration: 2-3 days
3D Printing & Assembly
We 3D print the shell components using industrial-grade printers and professional materials. Parts are post-processed (sanding, painting, finishing) as needed. We assemble the device into the new shell and perform functional testing.
Duration: 3-5 days
Quality Assurance & Delivery
Final testing ensures all device functions work correctly in the new shell. We verify wireless performance, thermal characteristics, port accessibility, and overall durability. Device ships with documentation and assembly instructions if disassembly is needed for travel.
Duration: 1-2 days
Rush Service Available
Need a custom shell for an upcoming engagement? We offer expedited design and production with 7-10 day turnaround for an additional fee. Contact us to discuss your timeline.
Materials & Finishing Options
We offer a range of materials and finishing options to match your requirements for durability, aesthetics, and environment-specific needs.
PLA (Standard)
Best For: Office environments, indoor use
Properties: Easy to print, good detail, biodegradable, various colors available
Finish: Matte or glossy coating options
ABS (Durable)
Best For: Impact resistance, higher temperatures
Properties: Strong, durable, heat resistant to 80°C, can be sanded and painted
Finish: Smooth surface with acetone vapor treatment
PETG (Balanced)
Best For: General purpose, chemical resistance
Properties: Strong, durable, food-safe, transparent options, moisture resistant
Finish: Semi-gloss natural finish
Nylon (Industrial)
Best For: High-stress applications, mechanical parts
Properties: Extremely strong, flexible, wear-resistant, chemical resistant
Finish: Textured surface, can be dyed
TPU (Flexible)
Best For: Shock absorption, gaskets, seals
Properties: Rubber-like flexibility, impact resistant, UV resistant
Finish: Matte rubber texture
ASA (Outdoor)
Best For: Outdoor deployments, UV exposure
Properties: Weather resistant, UV stable, temperature resistant
Finish: Matte finish, excellent color retention
Finishing Services
Surface Treatments
- Sanding & Smoothing: Remove layer lines for professional appearance
- Priming & Painting: Custom color matching to specific equipment
- Clear Coating: Protective clear coat for durability and UV resistance
- Texture Application: Add realistic textures (brushed metal, rubber, etc.)
Special Features
- Labeling & Branding: Apply realistic manufacturer labels, warning stickers, compliance marks
- Weathering: Intentional aging/wear to match older equipment
- Light Diffusion: Translucent sections for LED indicators
- Insert Molding: Embedded metal threaded inserts for mounting
Real-World Use Cases
How custom shells enable successful engagements
Corporate Office Infiltration
Challenge: Deploy network monitoring device in secured office environment
Solution: Network Module housed in phone charger shell left in conference room
Outcome: Device operated undetected for 2 weeks, captured credentials, mapped network topology
Manufacturing Facility Assessment
Challenge: Test IT/OT segmentation in industrial environment
Solution: Custom junction box shell matching facility infrastructure
Outcome: Device blended with building equipment, identified weak network segmentation between production and corporate networks
Healthcare Security Testing
Challenge: Assess medical device network security without alarming staff
Solution: Medical equipment aesthetic shell for Network Module
Outcome: Passed visual inspection by clinical staff, identified unencrypted patient data transmission
Government Facility Red Team
Challenge: Long-duration monitoring requiring inconspicuous device
Solution: Custom shell resembling building automation equipment
Outcome: 6-week deployment, device discovered only during final debrief despite multiple security patrols
Integration with PivotChip Devices
Our custom shells are designed specifically to work with our penetration testing device lineup, ensuring that discretion doesn't compromise functionality.
Antenna Optimization
Shells are designed with antenna placement in mind, ensuring Wi-Fi, cellular, and long-range communication performance is maintained or improved
Thermal Management
Proper ventilation designed into shells to prevent overheating during extended operations, critical for device reliability
Power Considerations
Shells accommodate various power options (USB, battery, PoE) with proper cable routing and connection access
LED Indicators
Status LEDs can be visible (for authorized access) or hidden (for covert operation) based on engagement requirements
Port Access
All necessary ports (USB, Ethernet, power) remain accessible while maintaining the disguise aesthetic
Device Protection
Shells provide physical protection against bumps, drops, and environmental factors while maintaining operational access
Device Compatibility Guarantee
All custom shells are designed and tested with the actual devices to ensure perfect fit and maintained functionality. If you're using our devices in your engagement, we guarantee the shell will work correctly or we'll redesign it at no additional cost.
⚖️ Ethical Use Requirements
Custom shell design services are provided exclusively for authorized security testing. All orders require:
- Proof of authorized engagement (statement of work, authorization letter, or contract)
- Professional credentials (OSCP, GPEN, CEH, or equivalent certification, OR employment by recognized security firm)
- Agreement to our Ethical Use Policy
- Clear description of intended use case and target environment
We reserve the right to refuse service if we cannot verify the legitimacy of the intended use. Custom shells designed to impersonate emergency services, law enforcement equipment, or life-safety systems will not be provided.
Ready to Design Your Custom Shell?
Contact us to discuss your engagement requirements and target environment. We'll help design the perfect disguise for your penetration testing devices.