Electrical enclosures are used to control and safety-proof delicate electronic products. They should be durable and weather-proof to protect the components they house. Because of this, die casting for electrical enclosures proves to be tremendously valuable for use in a wide array of industries.

What are the industries that use die casting for electrical components?

Telecommunications: One of the major players in the digital age, telecommunication is the industry that makes the most use of die-casting for electrical parts. Leading telecommunication companies have initiated requirements for manufacturing die-cast electrical enclosures and cabinets. Because of this, today’s telecommunication enclosures can withstand the severe weather conditions in the US.

Automotive: Many vehicular metal parts must be cast into specific shapes. Die casting is the perfect method for manufacturing these parts in this industry. Die casting produces an aesthetic appearance to these parts while providing the competencies of creating exclusive shapes with high durability.

Lighting: In the lighting industry, die casting produces non-toxic and lightweight lights. Die casting services for electrical enclosures also include manufacturing traffic lights and other lighting products.

Other Electronic Devices: Circuit boards, audio equipment, generators, and more are produced and furthered using die-casting processes.

What are the different enclosure die-casting applications in the community?

  • Telecommunication enclosures, especially those mounted on cell towers for wireless transmission
  • Cable TV amplifier housings to increase the signal from the central cable station to residential houses
  • LCD Frames, so LCD screen is protected by a rigid and sturdy metal frame to guard the electronics behind the screen
  • LED lighting boxes, especially those that need watertight applications
  • Generator housing for waterproofing of electric motors
  • For automotive electrical control units
  • Metal Chassis for the protection of circuit boards
  • Subwoofer equipment to increase sound quality and protect the speakers

How are electronic enclosures manufactured?

Enclosures, cabinets, and boxes are crucial to protecting the products they house, especially when placed in harsh environments. Industrial manufacturers extensively use these housings and boxes. Electric enclosures have a wide range of functions. They come in various shapes and sizes.

To build these boxes, sturdy and robust materials such as aluminum and zinc are ideally utilized. Designs are typically custom-made and individualized for the product to ensure a perfect fit. The enclosure must provide weatherproofing if the product is to be situated outdoors. It should protect small and electrical parts that could potentially be ruined by water or heat.

On the other hand, indoor products’ enclosures are also designed as cooling panels. Numerous panels are built with a series of fins close to the heat source. These allow the heat to be released from the electronics. Through this practice, the life of the electronic components is lengthened.

What is aluminum die-casting?

Aluminum die-casting is, first and foremost, lightweight. Another notable feature is that it can endure a high range of operating temperatures. Other properties that aluminum boasts are high strength, heat dissipation, corrosion resistance, and excellent electrical and thermal conductivity.

Aluminum die-casting also allows the creation of lighter parts and components. In contrast with other die-cast alloys, aluminum offers more options for surface finishing.

Why are aluminum die-castings advantageous to Use?

Possessing excellent electrical and shielding properties, aluminum is preferred for use in electronic components and housings. Aluminum die-castings are the ideal enclosures for electrical and electronic applications such as metering controls, CATV amplifier housings, automotive boxes, and industrial control units.

Aluminum die casts are effective enclosures for electrical circuitry because of additional features like RF shielding and weatherproofing. For heat sink transfer and dissipation, this alloy’s die casting can be built to serve many of the critical elements in circuits such as fins and standoff flat surfaces.

Aluminum makes it ideal for transferring heat from the components of a circuit board within the enclosure toward the outside. It reduces the interior temperature, so it protects the components from damage due to excessive heat. All these lead to its suitability for various outdoor enclosure applications.

What is zinc die-casting?

Zinc has been proven to be one of the most versatile die-cast metals. Compared to other die-cast metals such as aluminum or magnesium, it has the ability for higher precision with lower tooling costs. Zinc die casting also possesses a broad range of superb physical and mechanical properties and finishing characteristics. It is also the easiest to cast.

The most substantial advantage of using zinc is that it reduces tooling costs. Die-cast tooling can be a significant cost factor. Saving where and when you can is a valuable feature when choosing materials. 

Another great characteristic of zinc is its low melting temperature. Zinc die-cast can last up to ten times longer than aluminum die-casting and about five times longer than dies used for magnesium. It means that fewer repairs will be required with less downtime.

Why is zinc die-casting advantageous to use?

Zinc die casting has lower tooling costs, especially when the miniature zinc die casting process is used. It has longer tool life and can cast close to net-shaped complex geometries with thinner walls and less draft angle. It then reduces the need for shaping and thinning machine features.

Zinc has an excellent balance of mechanical and physical properties and higher yield strength and elongation. It also boasts good vibration dampening capacity compared to aluminum. A wide range of finishing options adds points to weatherproofing and aesthetics. If you have a limited project timeline, zinc is the viable choice as it has a faster production time.

SEI offers high-quality Aluminum and Zinc Die Cast Housings for your electronic housing needs. All our products exceed NEMA 4, NEMA 4X, and IP-65 requirements. We can ship your castings in two to four weeks. Minor modifications can be accommodated at the customer’s request. Plenty of our modified castings have become standard parts for our customers.

Our engineering and development assistance team will aid you in your design process. We also offer waveguide components and various finishing for your electronic parts. For more information about our products and how we can customize them for your project, call us at (408) 374-1031.