Key design considerations for sheet metal enclosures

Even the simplest electronic products require enclosures. Understanding the fabrication process of electronics enclosures can greatly enhance design quality and user experience. While some products are better suited for plastic enclosures, sheet metal enclosures offer significant advantages. They provide electrical conductivity, essential for EMI (electromagnetic interference) applications, emission reduction, external noise protection, and durability in harsh industrial conditions. The lightweight, non-corrosive, conductive, and strong properties of sheet metal make it especially popular in the electronics sector.

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Sheet metal enclosures encompass a variety of products, including RU server chassis, cabinets, rack components, PCBs, DIN rails, and weather-rated NEMA-style electrical boxes made from aluminum.

Preparing for Fabrication

Before discussing your needs with a sheet metal fabricator, it's crucial to familiarize yourself with basic sheet metal design concepts and common parameters for material selection.

According to Matt Garrett, an applications engineer for Rapid, part of Protolabs, "Sheet metal can seem like a mysterious dark art to some engineers or something overlooked until the last minute." A balanced approach recognizing the complexities of sheet metal can prove beneficial.

Garrett recommends understanding the following essential sheet metal design concepts:

• Maintain Uniform Wall Thickness: Sheet metal components are made from a single sheet. For instance, you cannot combine a 14-gauge base with a 16-gauge flange without welding two separately sourced elements.
• The 4x Rule (4x Material Thickness)
  • Flange lengths should be a minimum of 4 times the material thickness to ensure three points of contact with the tooling: two at either side of the bottom die and one at the center punch point.
  • Features like holes and slots must also be positioned at least 4 times the material thickness from the bend line to avoid distortion during forming. Since all features are initially cut flat, any critical features near a bend may incur additional machining costs.
• Avoid 3D Software Default Values for Bend Radii: Many design programs default to using material thickness as the bend radius, which does not reflect reality in press brake tooling. Standard radius tooling commonly used includes measurements ranging from .010" to 1.000".

Simplicity in Design

Simplicity in design and requirements is crucial for meeting tight time-to-market expectations. Achieving a cost-effective fabrication process that minimizes time and waste can enhance project success.

Garrett notes, "I've seen customers design themselves into corners. By the time they approach us, they have very little flexibility." 

For example, specifying punch features without flexibility, such as embosses or ribs, may necessitate custom tooling, which can be time-consuming and expensive. 

"I encourage customers to reach out with any questions before finalizing their designs," Garrett adds. "We are here to help." 

Rapid's sheet metal capabilities include laser cutting, punching, press brake forming, various welding methods, hardware insertion, and more.

Key Resource Links

• 8 Ways to Improve Sheet Metal Parts
• Why Tolerance Matters in Sheet Metal
• 3 Things You Need to Know About Forming Sheet Metal
• How to Get the Most Out of Sheet Metal Rapid Prototyping

Essential Questions for Choosing a Sheet Metal Partner

Your reputation relies on the quality of products provided to customers, making it vital to choose a trustworthy sheet metal fabrication partner. This process can be daunting due to various factors involved. Below are seven questions to consider when selecting a fabrication partner:

1. Are They Familiar with Your Industry?

Working with a partner familiar with your industry brings invaluable insights into quality standards and best practices. Their experience can lead to better production results.

ACE offers professional and reliable services.

2. What Equipment Do They Have?

Assessing the fabricator’s equipment is crucial. State-of-the-art machinery indicates their commitment to quality and positions them to meet project requirements effectively.

3. Do They Have Satisfied Customers?

Review previous projects and customer feedback. Understanding others’ experiences can help gauge the fabricator’s capabilities and reliability.

4. Do They Offer Customized Solutions?

Off-the-shelf products may not meet specific needs, so finding a partner who offers customization can enhance project outcomes. A focus on Design for Manufacturability and Assembly (DFMA) also streamlines production.

5. What Is Their Average Employment Tenure?

High employee turnover can affect product quality. Understanding staff tenure can provide insights into the company’s stability and experience level.

6. Can They Do Everything In-House?

In-house production ensures consistent quality. A provider handling all processes from design to finishing will provide a more reliable final product.

7. What Are Their Standards?

Ensuring the fabricator meets industry standards for quality is essential. Certifications from organizations like the American Welding Society (AWS) or ISO signify their commitment to high standards.

Does Estes Meet These Criteria?

Estes Design and Manufacturing, Inc. strives to fulfill all your sheet metal manufacturing needs. With experience across various industries, we leverage advanced technology to deliver quality products. Our ISO certifications in quality and medical device production further validate our high standards.

For more details on custom sheet metal enclosures, feel free to reach out to us.