Sheet Metal Enclosure Design: Material Selection and Manufacturing Techniques
Release time:2024-10-25 18:21:04
The process of creating a metal enclosure can be regarded as the process of developing a protective shell around your product. You should not only consider aesthetic aspects but also pay attention to protection, functionality, and production methods. And if you are doing it for the first time, then just take a deep breath! Correctly choosing the material and the right manufacturing techniques will ensure you a good design. In this article, we’re going to cover the major aspects so that you don’t feel helpless when you are required to make vital choices.
➔ Checklist
Understanding material types used in sheet metal enclosure
Overview of manufacturing techniques of sheet metal enclosure
Key tips for your sheet metal enclosure design
1) Understanding material types used in sheet metal enclosure
A sheet metal enclosure is made of thin metal sheets that you can use to encapsulate and protect electronic devices, machinery, or tools.
You know the materials you utilize affect the enclosure’s performance depending on its function or design. You should also consider the intended purpose of the product. Is it meant for an external or internal environment? Is it going to be exposed to chemicals, high temperatures, or moisture? All these questions inform the selection of appropriate materials. So, let’s discuss some common materails that you may use for designing your enclosure!
i) Stainless Steel: Anti-corrosive materials like stainless steel are the ideal option in terms of appearance and longevity. For instance, if you are thinking of an outdoor electrical cabinet, stainless steel is best as it can withstand harsh external atmospheric conditions because of its high melting points ( 1,370°C —1,530°C ). Moreover, stainless steel does not present a visual nuisance; it is made mandatory in situations when good appearance becomes important.
ii) Aluminum: Aluminum is best suited if you want a strong but light material. It is corrosion-resistant, which is why you can use it for outdoor enclosures. Such weight-saving configuration facilitates thermal dissipation within the electronic components, helping to keep them cool.
iii) Mild Steel:This type of material is cheap, easy to cut, and does not require excessive fabricating techniques, which makes it ideal for many electrical enclosure design projects. But the disadvantage is that if it is not painted or coated, it will rust. Therefore, when your enclosure is short on exposure to harsh conditions and needs to be installed inside, mild steel will be a boon.
iv) Galvanized Steel: Zinc-coated galvanized steels are much stronger against rust due to the zinc coating over steel. By using this material you will enjoy all properties of steel without any tension of having any kind of rusting.
Comparison table:
Melting points
Corrosion resistance
Best for
Stainless steel
1,370°C – 1,530°C
Excellent
In harsh environments, marine use
Aluminum
660°C
Good
Electronics, outdoor use
Mild steel
1,425°C – 1,540°C
Low
Indoor enclosures, budget-friendly
Galvanized steel
1,425°C (core)
moderate
Outdoor construction sites
2) Overview of manufacturing techniques of sheet metal enclosure
You know its not over but the material selection for the enclosure is just the beginning of the construction process. You also have to consider how these enclosures are manufactured, because this factor greatly impact the quality and cost of your enclosure. Here we are going to explore some of the most popular methods of manufacturing.
i) Laser Cutting
Laser cutting is a technology that ensures a sharp and detailed cut when cutting out complicated designs. Stainless steel, aluminum, and mild steel are materials that can be precisely cut using this technique. It helps cut down on the quantity of scraps, so you will also achieve cost savings.
Best for: Precise designs
Benefits: It gives a clean cut and hardly any waste.
ii) Bending
Enclosure design is one of the main parameters on which you pertain bending execution. It is the simplest operation, as it enables flat sheets to be folded into shapes of panels or edges effectively without the need for further fastening. In line with the required standards, the sheet metal could be bent with a press brake, and upon incorporation of other elements, the enclosure will be complete.
Best for: Enclosure peripheral ends, such as corners and panels.
Advantages: The procedure is fast, simple, and quite easy.
iii) Welding
If the enclosure is going to be heavily used and contain multiple metals, it will most probably be welded. Depending on the selected metal type, you can choose from a host of AR and MIG welding techniques. It goes without saying that welding will leave some marks that will need to be ground or painted over.
Best For: Applications with heavy-duty requirements
Advantages: Strong joints will have a longer lifespan
iv) Punching and Stamping
Punching and Stamping are employed when an enclosure needs holes or other patterned details. These procedures are fast and effective, especially when thrusting or punching in large quantities. This modification is also important because it affords uniformity in the appearance of your work.
Best For: Cutouts for enclosure ventilation or mounting components
Advantages: Fast and can be done multiple times
v) Coating and finishing
The next step that follows after the final assembly of all components of an enclosure should be coating or finishing. This coating procedure serves the purpose of enhancing both the strength and aesthetics of the enclosure by adding an additional layer. Examples commonly practiced are Powder coating, Painting, and anodizing.
Best For: Defending against rust and maintaining aesthetic appeal
Advantages: Better sustain and look
3) Key tips for your sheet metal enclosure design
In order to encourage easy and extended use of the enclosure, some design features which are considered essential for the final product are discussed.
i) Thinking on Ventilation and Distribution of Heat Generation
Air circulation becomes imperative whenever your box contains electronic devices or heat-generating devices. Otherwise, heat accumulation could eventually lead to component destruction or hinder equipment functionality. Design strategies might involve the use of vent holes, louvres, or fans to help boost airflow.
+Bonus Tip: Use Aluminum enclosures to efficiently dissipate heat. Aluminum is better than steel in this case. You must use filters to prevent dust and other particles from entering the enclosure’s seams.
ii) Add Tolerances and Variations
It should be understood that there is no such thing as complete quantitative production work with absolutely no errors. Processes like bending, punching, or welding, for instance, result in minor discrepancies in distances adopted, referred to as tolerances. In principle, these dissimilarities between pieces must already be taken into consideration during the design process.
+Bonus Tip: Use a little larger holes or flexible fittings so that one does not get intruded in the other due to different degrees of misalignment.
iii) Process the Assembly and Maintenance Methods
As it is highly advisable on many occasions, particularly if frequent repairs will be necessary, design systems that allow easy and rational assembly of your enclosure and its components. In order to avoid dust building up around the enclosure for no reason, make sure you use the appropriate fastening method, screws, hinges or snap-fit joins depending on how often access to the enclosure is required.
+ Bonus Tip: To minimize the time taken to assemble and install which is an exercise that requires exact precision, just pin point the areas where the mounting points are and punch them in advance. There should also be labels for access points and removeable panels for easy maintenance access.
iv) Selection of the Right Coating and Finish
The coating or final finish of the enclosure brings an appeal to the enclosure and is intended more as a decorative feature, and adds to the beauty of the enclosure. Coating finishes such as powder coats, paint, and anodizing provide surface protection from corrosion and abrasion. The chosen finishing quality must be in harmony with the material selected and the particular place which the enclosure is intended for.
+ Bonus Tip: Steel enclosures may be coated with a powder coating to eliminate or prevent rusting. A suitable color or finish must be chosen for the design and character of the product to suit its environment.
v) Gauge the Weight and Portability Features of your Enclosure and Its Parts
This is particularly so if the enclosure will be relocated frequently or if it will be fixed in a remote location. Nevertheless, for portable enclosures, Aluminium of metallic nature is most appropriate owing to its lightweight characteristics. For heavy duty applications, stainless steel will do well but is quite heavy for such applications.
+ Bonus Tip: The use of brackets or handles on the carrying cases will assist in order to facilitate transportation of the enclosures.
vi) Prototype testing for the Desired Design
The final step is to proceed and execute the design that has been shaped in the last stage and create a model. A few models allow mass production of a number of units and model design where every problem in the design has been solved. Problems like fit, function and aesthetics can be handled in the early stages of related developments thus saving cost and time.
+ Bonus Tip: Make use of rapid 3D modeling software even before any 3D prototyping is made. Every time you run it try to bring in the manufacturing team for design directive comments.
Saipwell is a subsidiary of Saip Electric Group and is a leader in the global enclosure market. Its main business involves the manufacturing of electrical and IT enclosures, assembly of whole electrical switchgear systems and development of enclosures for use in new energy solutions
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