Many electronic devices share at least one characteristic: the circuit boards and other components that enable them to function are all contained within an enclosure despite their diverse applications.
A custom-designed enclosure can assist consumer and computer electronics products in distinguishing themselves from commoditized competitors. Other enclosures provide more practical advantages, such as safeguarding industrial and other equipment from chemicals, heat, or moisture, among other hazards. The advantages and disadvantages of each process for the production of enclosures are discussed in this introduction, which encompasses design considerations, material and assembly options, and advanced manufacturing techniques.
What are the various varieties of electrical enclosures?
A wall-mounted enclosure is suitable for the internal storage of electrical components and the protection of sensitive equipment in areas that may be exposed to excessively wet conditions.
In the same vein, floor-mount and free-standing electrical enclosures are appropriate for systems that incorporate large components or complex mounting configurations.
In addition, trough enclosures are used to protect cables from water and corrosive elements in a variety of applications. Your distinctive and precise specifications are met by the custom-designed and constructed electrical enclosure.
Common Techniques for the Production of Electronics Enclosures
Ultimately, the most efficient manufacturing method for a specific electronics enclosure will be determined by the material selection. The following are some of the most frequently employed methods:
CNC Machining
The primary rationale for employing CNC machining to manufacture electronic enclosures is its rapidity, as the parts are prepared within one to three business days. More intricate designs can also be machined; however, they may require a lengthier production time. In contrast to other manufacturing methods, CNC machining allows for the integration of greater geometrical complexity into part design while maintaining superpart tolerances. This is in contrast to the relatively basic housings that can be produced using other methods. Another benefit of CNC machining is that enclosures that are machined from a single metal workpiece will not exhibit any exposed seams, resulting in a visually appealing and clean product. Nevertheless, it may not be a cost-effective solution to hollow a block of material on a mill, as you are likely spending more money on the material than you will ultimately use in the final product. Our CNC machining process employs the majority of the plastics available for injection moulding and the majority of the metals used in sheet metal fabrication, in addition to the fact that machinable parts are highly durable.
Types of materials that are suitable for CNC machining enclosures
Enclosures can be manufactured from a variety of materials, including engineering plastics, stainless steel, brass ,and aluminium. Aluminum is the most frequently selected material for CNC machining enclosures due to its lightweight nature, low cost of basic materials, and availability in a wide range of sizes.
Fabrication of Sheet Metal
Enclosures that are fabricated from sheet metal are relatively simple to finish professionally, as they are well-suited for powder coating. Powder coating is recognized for its exceptional durability and weather resistance despite its relatively low cost. Anodizing and chromate plating are additional coatings that are frequently employed on enclosures that are constructed from sheet metal.
Common examples of enclosures constructed through sheet metal fabrication include the cases of desktop computers and numerous outdoor electronics enclosures. Despite their lack of aesthetic appeal, they compensate for it with their durability. The initial costs of tooling associated with sheet metal fabrication can be substantial; however, the price per part decreases swiftly as production volume increases.
3D printing
3D printing, is a process that involves the creation of parts by layering material using CAD files. This process frequently enables the condensing of multi-part assemblies into single pieces. The addition of features such as curved internal channels, which are extremely difficult or impossible to produce via other methods, is made possible by the greater geometric latitude that 3D printing provides.
There are no establishment fees, and the lead time is extraordinarily brief. Designing is effortless due to the minimal constraints regarding shape. This enables the creation of highly imaginative shapes without the fabrication limitations of other methods. Multi Jet Fusion and selective laser sintering are optimal for low-volume production. Although orders for smaller enclosures may readily range into the thousands, this could involve hundreds of parts. Additionally, nylon powder bed technologies are among the quickest 3D printing processes, which is why they typically have the lowest per-part cost, particularly when purchasing in larger quantities.
A plastic filament is melted and deposited onto a heated plate layer by layer by FDM printers, the earliest and most prevalent 3D printing technology. FDM is a technology that is well-polished, accessible, affordable, and ubiquitous, which is why it continues to hold significant value in the prototype manufacturing sector. Nevertheless, the application sectors for FDM are becoming increasingly restricted due to the declining cost of the SLS and MJF prints, which are, in general, superior.
Injection molding
The injection moulding process enables the production of identical parts in large quantities by repeatedly and swiftly filling durable metal moulds with molten plastics. The product development cycle is reduced by weeks, and in some cases, months, by the prototype injection moulding process, which produces parts within days. This method of prototyping can be more expensive when iterating prior to production; however, it can also function as a transition to production. Our on-demand manufacturing procedure provides an unlimited number of shots from each mould as customers seek to purchase larger quantities of parts. Manufacturers frequently employ this technique to fabricate basic enclosures from rigid or non-rigid plastics, including those utilized in game controllers, kiosk displays, and numerous other products.
Testing of Enclosures
It is crucial to test the completed electrical enclosure to guarantee that it satisfies all necessary specifications following the manufacturing process.
Enclosure testing can also be conducted through a variety of methods, including:
Salt Mist Test: This test involves subjecting the enclosure to a salt mist. The enclosure’s corrosion resistance is evaluated during the test.
Humidity Test: The humidity test is designed to ascertain the impact of protracted exposure to high humidity on the enclosure.
Thermal Shock Test– This test is conducted to verify the enclosure’s material selection or to confirm that it can withstand the thermal disturbances it may encounter in its intended environment.
Ingress testing: This is conducted to ensure that the enclosure complies with various enclosure ratings, such as IP, and to ensure its longevity.
Test of Vibration– This test is performed to guarantee that the enclosure can withstand the vibrations that it will encounter in its intended environment.
Maintaining the long-term functionality of electronic devices becomes increasingly critical as digital technologies become more deeply ingrained in daily life. While electronics enclosures offer essential protection, engineers and product teams must guarantee that the material selection and part design are optimized to achieve the greatest possible benefit. By selecting a professional manufacturing partner, you will have direct access to our decades of collective expertise and knowledge.
