A ruggedized, compact personal information appliance apparatus and process of manufacture is disclosed. The apparatus discloses an information appliance surrounded by an encapsulation element. The encapsulation element isolates predetermined exterior portions of the appliance from a predetermined set of environmental conditions. The process of manufacturing discloses: identifying a predetermined set of environmental conditions; identifying a predetermined set of structures on the appliance, which are to be protected from the environmental conditions; selecting an encapsulation element which can protect the appliance from the environmental conditions; and surrounding the set of structures with the encapsulation element.