Machined Enclosures – The Basics

Machined enclosures are protective cases or housings made from solid material, typically metal and/or plastic, built using automated CNC machines.

The process involves using CNC mills to cut, carve and shape raw material into customized enclosures with precision and intricate detailing. The computer-controlled process minimizes errors and executes complex designs with high accuracy.

At Protocase, we have many different metals such as aluminum, steel and stainless steel as well as plastics such as acetal, UHMW, acrylic and polycarbonate which we can use to build enclosures using CNC machining. Among these materials, aluminum is the most popular one, as it’s very easy to machine.

Why Use Machined Enclosures?

Precision

Sheet metal fabrication produces highly precise enclosures, but machined enclosures offer slightly greater accuracy.

Customized Designs

You can cater to specific project needs – whether you need intricate cutouts, threaded holes, or unique shapes like pockets or grooves, CNC machining can handle it.

Durability

On top of that, CNC machined enclosures are tough enough to handle harsh environments that include heat, moisture and any physical impact.

Sure, machining costs more than sheet-metal fabricated enclosures, but it delivers ultra durability and precision. You get enclosures with amazing precision, making it a smart choice, especially when you’re working on prototypes or low to medium production.

Prototyping

It is especially a great option when you’re prototyping, as you can quickly turn CAD designs into functioning enclosures, enabling faster testing and iteration during product development.

Flexibility

The flexibility of the subtractive manufacturing process makes machined enclosures highly popular. This lets you place component mounting locations anywhere, offering incredible versatility and an unmatched range of possibilities.

For machined enclosures, standoffs can be any thread size, diameter or height, ensuring a perfect fit. In contrast, sheet metal standoffs are premade and may not fit as precisely.

You also get full control over the exterior. Machined enclosures generally look cleaner, as the exterior is made from a single piece rather than multiple flanges meeting at corners.

Applications of Machined Enclosures

Aerospace

Machined enclosures are a big deal in the aerospace industry since they need to handle extreme conditions without adding too much weight.

Electronics

They’re also widely used in electronics, where precision electronic devices need protection for sensitive components like PCBs, sensors and batteries.

Industrial Equipment

You’ll find them in industrial equipment too, where they house things like gears, motors and other mechanical parts.

Other Uses

The automotive and healthcare industries widely use machined enclosures as well.

Design Tips

First off, remember that while CNC machines can handle complex shapes, simplifying your design can save time and be cost-effective.

If you have an enclosure with holes or slots on multiple faces, consider moving those details to the same face if possible. This will cut down on setup costs and save you some money.

Also, with machined enclosures, thick side walls are not hugely beneficial since they can make the case heavy. That said, they do make manufacturing easier because thicker walls are quicker to machine than thinner ones. With thinner features, it is necessary to slow down the cutting process and use additional work holding, which will lead to longer lead times. So, try to strike a balance.

Next, if you’re working on electronic enclosures, think about adding vents or heat sinks to help with heat dissipation. For example, our sister company 45HomeLab adds fins to the top of their cases. This is to boost surface area, as more surface area means better heat dissipation.

And, of course, start with prototypes to identify and resolve design flaws before committing to a full production run. This will save you a lot of hassle down the line!

Conclusion

In conclusion, CNC machined enclosures offer incredible precision, durability and customization options, making them an excellent choice for projects that demand high-quality protection for sensitive components. 

Powered by High Velocity Mass Customization (HVMC), at Protocase, we make it easy to create custom machined enclosures. We’ll manufacture your enclosures, add any finishes you want and include fasteners or other hardware – in as fast as 2-3 days.

By partnering with us, you can meet your deadlines, accelerate iterations and keep your projects on track.

Have a design ready? Get an instant quote today!