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Sheet Metal Enclosure Design: Key Enclosure Design Tips!

sheet metal

Sheet Metal Enclosure Design: Key Enclosure Design Tips!

No electronic product would be complete without a case or cover. If an electrical product is big or complicated, it must be in an enclosure to keep it safe from the outside world. With a sheet metal enclosure, you can cut down on emissions. It makes it more durable in harsh industrial environments.

The ultimate goal of a sheet metal fabrication company is to make a high-quality product. A high-quality case for electronic parts helps to achieve this goal. Sheet metal enclosures have their own set of rules.

These tips will make your job easier and help you get better results. Here are some tips for making a sheet metal enclosure that will help you keep up with the times. Let’s start right away!

Know the Product Design Requirements!

It is important to know what the product looks like and how it works throughout the design process. Making a sheet metal enclosure is the same. The more you know about these things, the easier it will be to make a sheet metal enclosure that meets your needs.

The following are some of the things you should know about the products you want to buy:

  • The use of sheet metal cover.
  • The conditions in which the enclosure will work, like temp, corrosion exposure, and the IP rating.
  • Specs on how big things are.
  • There is a wide range of mounting options, such as wall, pole, and tabletop.
  • The component you want to put inside the enclosure, including its height and width.
  • The locations of its connectors and other parts.
  • Needs in terms of how they look.

Choose a Material for the Design of a Sheet Metal Enclosure!

The next thing to do is choose a metal that fits your needs. The use of your sheet metal enclosure will help you decide what kind of metal to use. You don’t want to choose a metal that will quickly break down in a particular place.

It’s essential to choose metals that can withstand corrosion and wear. Before we go any further, look at the properties of the best metals to use for your enclosure.

Sheet Metal

· Aluminum

There are two good things about this material: It is resistant to corrosion and lightweight. At times, it is not as strong as steel.

There are many different types of aluminum, and each one is different. There are two primary aluminum alloys in sheet metal enclosures: 6061 and 6063, each of which has its own name.

If you bend 5052 aluminum, it won’t break. This alloy is easy to machine and weld, making it good for sheet metal enclosures.

But, 6061 aluminum is more likely to break than the other aluminum alloys. It is machine-friendly.

Aluminum is a good material for sheet metal parts and enclosures because it is light and doesn’t rust. Anodizing aluminum parts may give them a long-lasting and protective finish keeping them safe. Chromate coating is a good choice for a part that needs to be near electricity.

· Stainless Steel

This alloy has nickel and chromium in it. So, corrosion resistance will be much better. In terms of strength, stainless steel is a lot better than aluminum.

You can use it to make them more durable when making enclosures out of sheet metal for high-impact devices. A grained finish on stainless steel gives it a unique look that stands out.

· Galvanneal

Low-carbon steel that has been zinc-coated and annealed is what this is made of. Annealing is used to ensure that the zinc is stuck to the surface. So, you can be sure there won’t be any flaking off when you bend or shape.

Galvanneal is the best choice if you want to use the metal enclosure in a wet place. For it to be resistant to corrosion, it needs to have a specific type of coating on top of it.


An annealed steel that is rolled very close together is a good choice for indoor enclosures and parts that must be kept clean. It’s also very strong and rigid at the same time. It has the best chance of being around for a long time when it’s inside.

When left uncoated, CRCA is vulnerable to corrosion. This can cause rust because it is not strong enough.

· Copper

Copper is a good metal, but it’s not usually used in sheet metal enclosure design. It’s a good conductor of heat and electricity. As a result, electrical applications can be used.

There are only a few enclosures made of copper because it’s too fragile to stand up to a lot of weight. Copper is best used for bus bars or other things.

We can’t fully help you design a sheet metal enclosure if you don’t know what to look for when purchasing metal. Before choosing a metal for your project, think about the following things.

  • When something is stretched, it has high tensile strength.
  • Weldability and the ability to make things by hand and machine.
  • There is a lot of corrosion resistance.
  • There is wear resistance.
  • The weight of electronic enclosures must be kept in check.
  • Easy to put together
  • The ability to move heat and electricity
  • Cost

Choose Suitable Shape of Enclosure!

Another essential sheet metal enclosure design tip is to pick the right shape for your enclosure.

When you design the PCB and the system, think about how the enclosure will look when you’re done with it. You can avoid a lot of the most common design flaws.

sheet metal

Compared to making plastic enclosures, sheet metal may be a little more limited in what you can do. However, if you use these shapes, you can make helpful, cost-effective, and visually appealing enclosures.

· Folded Box Shape

In a box with a lid that comes, it has four sides. Easy access for service and more mounting options are made possible because this enclosure has a unique shape.

· F-Shape

An enclosure in this style doesn’t take long at all to make. PCBs with connections on both sides work well in an F-shaped case.

· L-Shape

People can easily figure out how to build an L-shape enclosure because it’s simple. Besides being easy to understand, the geometry makes it easy to use as well.

· U-Shape

In the same way as F-shape boxes, U-shape boxes are also easy to make. They usually have strong bases and are easy to get to for repairs.

Understand Sheet Metal Thicknesses!

When it comes to making enclosures, the thickness of the metal is very important. The thickness of the enclosure is often a factor in its strength, weight, flange length, and punch size.

In general, thick metals are more difficult to work with than thinner metals, which you may have already known. In addition, to make large parts with more strength, you need to make the material thicker.

There doesn’t seem to be a lot of difference between the different thickness gauges on paper. However, if you know more about sheet metal gauges, you can figure out which option is best for your project.

Keep in mind that a sheet metal enclosure must always be made with a uniform thickness of wall all the way around. This is a good way to see how well the part is made.

Bend Radius Should Be Consistent!

The Bend radii should always add up to the thickness of the content. The width of the product should be the same as the Bend radius. CAD software will help you calculate your metal’s bend allowance digitally. It would be best always to consider your enclosure’s functional and aesthetic requirements.


The spraying of paint on the surface of your metal is part of the painting process. In general, your sheet metal enclosure will look better because of it. People will be able to recognize your brand more quickly as well.

Prototypes and Validation Testing Should be Done!

With the help of the sheet metal enclosure design ideas above, you will have a working idea. Next, the design needs to be changed to meet the customer’s needs and improve manufacturing efficiency.

Prototyping is the best way to get this done quickly and efficiently. New product development is important for companies that make sheet metal.

In the next step, your design will be put through its paces in the real world of work. But, your customers may not be happy with the prototype you made for them.

Testing is very important, and it can’t be overstated. Decisions can be made about whether to make things on a large scale here.

You can do validation testing by using the product or performing simple tests in the outside world. You might find places that need to be changed and improved.

sheet metal


There are a lot of benefits to using sheet metal enclosures. They improve electrical conductivity, cut down on pollution, and withstand harsh industrial environments.

Also, they help to cut costs and turnaround times. People should make sure they are done right because of this. You can use the sheet metal enclosure design advice given to make the best decisions for your project.

When you are in the hands of experts, there is no better way to go. You can buy this through QBH Technology. QBH sheet metal processing has a lot of good things about it.

Sheet metal enclosure design is one of the skills of their very talented team. You will also benefit from the automated and streamlined production services they offer.

You’ll get the best results because they have strong manufacturing, quality assurance, and technical skills.

Custom machined parts with detailed dimensional reports are available for an immediate quote request. QBH Technology’s customer service department can help you get started. You can send them your design files or send them an email to get help.

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Alice Tang

Rapid Manufacturing Expert

This is Alice from QBH Technology.I have been focused on sheet metal and CNC machining parts for more than 5 years now,and the purpose of this article is to share with you the knowledge related to sheet metal and CNC machining from a Chinese manufacturer.

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