Extruded Enclosures: Top 4 Design Considerations

Extruded aluminum enclosures are a durable and versatile solution for protecting electronic components.

These enclosures consist of two aluminum extrusions (side rails) combined with front, rear, top and bottom panels, and provide a robust and efficient housing option.

One of their standout applications is in creating PCB enclosures, as you can slide the board into one of the extrusions to effortlessly mount and secure it. They are also used to house components like telecommunications equipment, industrial controls and power supplies.

Our extrusions are made from 6063 aluminum. To fit the slots in the aluminum extrusions, the top and bottom panels need to be 0.064″ (mm) 5052 aluminum. For the front and rear panels in an extruded aluminum enclosure, 5052 aluminum is usually used too, but you can also choose from any of our stocked sheet metal options.

Extruded enclosures are a popular choice because they’re simple and cost-effective. You can even combine extrusions to create a sloped case, known as an extruded consolet enclosure.

At Protocase, we offer two stocked extrusions for quick customization to meet standard height requirements:

• 1U Height: 1.72″ | 43.688 mm
• 2U Height: 3.47″ | 88.138 mm

And we specialize in custom-manufacturing fully finished extruded aluminum enclosures in as little as 2–3 days, with no minimum order requirements. This level of flexibility ensures you get exactly what you need, when you need it.

If you’re designing an extruded aluminum enclosure, there are several important considerations to ensure both functionality and durability. Therefore, let’s dive into four key factors to keep in mind.

1. Getting the Dimensions Right

An important step involves ensuring the enclosure’s internal dimensions are suitable for your application. Your enclosure needs to accommodate all components and PCBs while leaving room for proper alignment and operation.

Key tips:

• Plan for all wiring and connectors to fit comfortably.
• Ensure cables are organized and easy to access for future maintenance.
• Factor in compatibility with other equipment or systems.
• Account for clearances and tolerances during manufacturing to ensure smooth assembly and operation.

2. Planning for Mounting

Mounting your components securely is essential for both performance and reliability. Extruded aluminum enclosures typically feature integrated slots to simplify PCB mounting, but a little extra planning can make installation even easier.

Key tips:

• Include mounting holes, brackets, rails, or additional slots for flexibility.
• Ensure that your mounting solution keeps all components stable and secure during use.

3. Thermal Management

Efficient thermal management is crucial to prevent overheating and maintain the long-term performance of your enclosure. Aluminum’s natural heat-dissipation properties can work in your favor, but additional strategies might be necessary.

Key tips:

• Incorporate heat sinks, ventilation holes, or fan mounts to improve airflow.
• Place heat-generating components where airflow is maximized.

4. Adding Surface Finishes

While structural functionality is the primary focus, adding a surface finish can enhance the protection and/or appearance of your enclosure.

Do note that the aluminum extrusions for the front and rear of the extruded consolet come in a bare mill finish, but you can add a secondary finish if needed.

Popular surface finishes:

• Chemical Conversion Coating: Provides extra protection and durability.
• Powdercoating: Offers a smooth, clean finish for a polished appearance.

You can mix and match finishes or even powdercoat colors.

Conclusion

Designing extruded aluminum enclosures requires careful consideration of dimensions, mounting, thermal management and finishing options. While there are other considerations to keep in mind, we believe these four are the most important.

Taking the time to plan these aspects will ensure your enclosure not only meets your functional requirements but also stands the test of time.

Protocase can help you create extruded aluminum enclosures customized to your exact needs. Furthermore, with our rapid manufacturing capabilities, we can custom-manufacture fully-finished enclosures in just 2–3 days and there are no minimum order requirements.

Need Help with Your Design?

If you have questions or need assistance, reach out and we can help you out! Email us at info@protocase.com or fill out the Contact Us form on our website.

Also, remember, our in-house design software Protocase Designer includes templates for all of our 1U and 2U extruded cases, with various front and rear panel options to suit different preferences.