Products & Services
Protocase manufactures fully finished custom electronic enclosures and associated parts from a wide variety of materials and components, in 2-3 days with no minimum order. Protocase also provides expert and affordable enclosure design services.
Aluminum
Aluminum is corrosion resistant and light weight.
It has a lower structural stiffness than steel (about 1/3), which must be compensated for by thicker gauge.
Finish:
Powdercoat, No Finish or Grained Finish
Fasteners:
Typically, stainless steel fasteners are used with aluminum. However, in some cases, zinc-plated fasteners are used, depending on the application.
- → 5052 Aluminum - H32
- → 6061 Aluminum - ( Sheet/Plate )
- → Aluminum 7075-T6
- → Aluminum 2024-T3
- → Aluminum Alca 5 Plate
Stocked Aluminum alloy ( Sheet/Plate )
5052 Aluminum - H32
5052 Aluminum is optimal for sheet metal work and is very easy to form at room temperature. This material is very bendable, and can therefore handle tight radii. A non-heat treatable alloy, 5052 aluminum is readily welded by conventional methods. It has good forming characteristics and good corrosion resistance, including resistance to salt water. 5052 aluminum is also relatively easy to machine.
| Gauge | Thickness | Thickness Tolerance |
|---|---|---|
| (0.250" | 6.35 mm) | ± 0.014" | |
| (0.188" | 4.78 mm) | ± 0.009" | |
| 8 gauge | (0.1285" | 3.26mm) | ± 0.007 | ± 0.18mm |
| 10 gauge | (0.102" | 2.59mm) | ± 0.006 | ± 0.15mm |
| 11 gauge | (0.091" | 2.31 mm) | ± 0.0045" |
| 12 gauge | (0.081" | 2.06 mm) | ± 0.0045" |
| 14 gauge | (0.064" | 1.63 mm) | ± 0.0040" |
| 16 gauge | (0.051" | 1.30 mm) | ± 0.0035" |
| 18 gauge | (0.040" | 1.02 mm) | ± 0.0035" |
| 20 gauge | (0.032" | 0.81 mm) | ± 0.0030" |
6061 Aluminum - ( Sheet/Plate )
Aluminum is a general-purpose alloy commonly used in extrusions, and is also available in sheet metal. However, it
is not recommended for sheet metal work because it tends to crack on the outside radii once it passes its yield
(and therefore requires a much larger radii to be able to bend properly). 6061 aluminum is also very easy to machine.
Temper:
Thicknesses above 0.188” have a temper of T651.
Thicknesses 0.188" and below have a temper of T6.
| Gauge | Thickness | Thickness Tolerance |
|---|---|---|
| (0.102" | 2.6mm) | ± 0.006" | |
| (0.1285" | 3.26 mm) | ± 0.007" | |
| (0.188" | 4.78 mm) | ± 0.009" | |
| (0.250" | 6.35 mm) | ± 0.014" | |
| (0.375" | 9.53 mm) | ± 0.017" | |
| (0.500" | 12.7 mm) | ± 0.023" |
Aluminum 7075-T6
7075 Aluminum is predominantly alloyed with zinc. Among aluminum alloys, it is one of the highest strength options, making it optimal for aerospace and defense applications, as well as rock climbing gear, bicycle components and mold tool manufacturing.
| Gauge | Thickness | Thickness Tolerance |
|---|---|---|
| 16 | 0.050" | 1.27 mm | ± 0.002" | 0.0508 mm |
| 14 | 0.063" | 1.6002 mm | ± 0.002" 0.0508 mm |
| 12 | 0.080" | 2.032 mm | ± 0.0025" | 0.0635 mm |
| 11 | 0.090" | 2.286 mm | ± 0.0025" 0.0635 mm |
| 10 | 0.100" | 2.54 mm | ± 0.0035" | 0.0889 mm |
| 0.125" | 3.175 mm | ± 0.039" | 0.9906 mm | |
| 0.250" | 6.35 mm | ± 0.075" | 1.905 mm | |
| 0.500" | 12.7 mm | ± 0.130" | 3.302 mm | |
| 1.000" | 25.4 mm | ± 0.039" | 0.9906 mm |
Aluminum 2024-T3
2024 Aluminum is predominantly alloyed with copper. It is common to find it used in the aerospace and defense industries because of its high strength-to-weight ratio. It requires protective coating in many use cases.
| Gauge | Thickness | Thickness Tolerance |
|---|---|---|
| 16 | 0.050" | 1.27 mm | ± 0.002" | 0.0508 mm |
| 14 | 0.063" | 1.6002 mm | ± 0.002" 0.0508 mm |
| 12 | 0.080" | 2.032 mm | ± 0.0025" | 0.0635 mm |
| 11 | 0.090" | 2.286 mm | ± 0.0025" 0.0635 mm |
| 10 | 0.100" | 2.54 mm | ± 0.0035" | 0.0889 mm |
| 0.125" | 3.175 mm | ± 0.039" | 0.9906 mm | |
| 0.250" | 6.35 mm | ± 0.075" | 1.905 mm | |
| 0.500" | 12.7 mm | ± 0.130" | 3.302 mm | |
| 1.000" | 25.4 mm | ± 0.039" | 0.9906 mm |
Aluminum Alca 5 Plate
Aluminum Alca 5 Plate is cast plate known for its stability and consistency between plates. It has superior flatness and
dimensional tolerances on the thickness which makes it popular for tooling and base plates.
Alca 5 is similar to MIC 6 Aluminum. If your project specifically requires MIC 6, we are happy to order it for you as a non-stock request.
| Gauge | Thickness | Thickness Tolerance | Flatness Tolerance |
|---|---|---|---|
| (0.250" | 6.35 mm) | ± 0.005" | 0.13mm | 0.015" | 0.38mm | |
| (0.375" | 9.53 mm) | ± 0.005" | 0.13mm | 0.015" | 0.38mm | |
| (0.500" | 12.7 mm) | ± 0.005" | 0.13mm | 0.015" | 0.38mm | |
| (1.000" | 25.4 mm) | ± 0.005" | 0.13mm | 0.005" | 0.13mm |
Please note: Our suppliers have provided the material data above, with the nominal thicknesses based on industry standards.
Note: Gauges are typically not used when specifying aluminum as the actual thickness of the aluminum is more internationally recognized. It starts at sheet by thickness and migrates into plate at the thicker end of the scale.