Key Sheet Metal Enclosure Design Tips

Sheet metal enclosures are critical for electronic products, and the importance cannot be stressed enough. Regardless of the size and complexity of electrical products, having some enclosure is crucial. A sheet metal enclosure has more benefits like electrical conductivity, emission reduction and protection against harsh industrial environments. In addition, every sheet metal case manufacturer wants to ensure general design success that results in a positive user experience. Here are key design tips when selecting a custom sheet metal enclosure.

Understanding Product Design Requirements

First, it is crucial to understand a product's aesthetic and functional requirements in all the design processes. When designing a sheet metal enclosure, understanding the requirements ensures that the sheet metal case meets your needs. Some product requirements to consider include;

Material Selection for Sheet Metal Enclosure Design

After understanding the product requirements, it is crucial to consider the type of metal that works best for the metal enclosure. The best material to consider is aluminium which offers premium quality while being wear and corrosion-resistant.

Aluminium Sheet Metal Enclosures

Aluminium has a lower stiffness level than steel, especially 5052 Aluminium and 6061 Aluminium. However, 5052 aluminium has better bending capabilities even to a tight radius without cracking. The 6061 aluminium is also easy to machine, only that it can crack when bending in tight radii.

Suitable Enclosure Shapes

Considering the enclosure shape at the PCB and system design level is critical. The following sheet metal enclosure shapes are cost-effective and aesthetically pleasing.

This shape gives a classic four-sided shape with a lid for easy access during service and an extensive array of mounting options.

F-shape enclosures are easy to produce and great for sheet metal enclosures with connectors on opposite sides.

An L-shape project box is straightforward with easy-to-understand geometry that offers easy access.

The U-shape sheet metal case is also easy to produce and has solid bases for easy access during service.

Sheet Metal Thickness

Sheet metal case thickness determines an enclosure's weight, strength, flange length and punchy size. Therefore, it is hard to make smaller products from thicker materials. Moreover, increasing material thickness is great for designing stronger and larger parts.

While most thickness gauges may seem equal, understanding sheet metal gauges are crucial.