Aluminum Enclosure Extrusion
Aluminum Enclosure Extrusion & Electronics Enclosures
Extruded aluminum enclosures for drives, inverters, EV chargers and batteries — with machined openings, IP-rated seals, EMC options and integrated heatsink walls, made to your drawing.
One section, not three suppliers
An extruded enclosure is a hollow profile with walls shaped for your board, connectors and heat path — then machined and finished in-house.
The advantage of extrusion over a die-cast or sheet-metal box shows up where the enclosure does more than hold a PCB. The side wall can be the heat path: a finned external surface or a flat internal face mated to a module. The end faces can carry machined connector cutouts, threaded inserts and gasket grooves — all cut in one setup referenced to the extruded datum, so the lid seats square every time.
Because the shape is tooled to your drawing, you are not designing around a catalog box. The wall thickness, groove position and mount pattern follow your assembly, not a standard part. For recurring volume this is usually cheaper per unit than fabricating the same box from plate, and it is stiffer than thin sheet metal.
Enclosure types we build
Matching the form to the environment and the electronics inside.
Electronics enclosures
Standard aluminum electronics enclosure bodies for power supplies, controllers and instrumentation, with machined end plates.
Project & custom enclosures
Custom aluminum enclosure shapes for a one-off product or a low-volume run where a stock box will not fit the layout.
IP-rated / waterproof
Waterproof aluminum enclosure with gasket groove and sealed end caps for outdoor and wash-down use. IP class confirmed against your requirement.
EMC-shielded
Conductive anodize or plated surfaces and tight seams for electromagnetic compatibility — specify the test level in the drawing.
Heatsink enclosures
Walls that are the thermal path: finned outside, flat inside. See our heatsink range for the thermal design.
Battery & EV enclosures
Housings for EV chargers, battery modules and power electronics — see the power electronics application.
Typical capabilities
Indicative ranges; exact IP class, EMC method and tolerance are confirmed against your drawing.
Alloy
6063 typical for corrosion and finish; 6061 where walls carry load. Tempers T5 / T6.
Wall & stiffness
Walls ≥ 1.0 mm typical. Thicker walls and internal ribs raise stiffness without a heavier overall section.
Sealing
Gasket groove extruded or machined into the profile; end caps bolted or welded. IP class confirmed per requirement.
EMC
Conductive anodize / nickel or tin plating on contact surfaces; continuous seam path for shielding.
Machining
Connector cutouts, threaded inserts, faces and holes on CNC, referenced to the extruded datum (±0.01 mm typical).
Finish
Anodize Type II / III or powder coat (RAL and custom), including IP-rated color marking.
Capability figures are typical production ranges. IP class, EMC method and tolerance are confirmed against your drawing before tooling.
Design notes for enclosures
What decides whether an extruded enclosure is the right choice.
Heat first. If the enclosure dissipates power, design the finned wall early. An extruded fin wall is far cheaper than bolting a separate heatsink to a plain box, and the thermal path is continuous.
Sealing groove. A gasket needs a channel with a controlled width and a flat seating face. Extruding the groove into the profile is cleaner than milling it later. Tell us the gasket cross-section.
Mounting. Threaded inserts, through-holes or studs — decide where they land. Machining them into the extruded end is more accurate than welding a plate on.
Lid and split line. An extruded body is open along its length; the ends (and sometimes a removable face) close it. Plan the split so the gasket and screws are accessible and the seam does not cross a functional surface.
Questions buyers ask
Short answers before you send a drawing.
Extruded vs die-cast aluminum enclosure — which?
Die-casting wins for complex, thin-wall, high-volume boxes with many integrated features and no length axis. Extrusion wins when the enclosure is long or follows a profile, when wall acts as a heat path (finned), or when volume is too low to justify a die-cast tool. Extruded enclosures also give a continuous, stiff section and easy integration of grooves and fins. For a power supply or inverter housing with a thermal wall, extrusion is usually the better fit.
Aluminum vs plastic enclosure?
Plastic is lighter and cheaper at very high volume and insulates electrically, but it softens with heat, ages under UV and offers weak EMI shielding. Aluminum dissipates heat, shields EMI naturally, and survives outdoor and industrial use. Choose aluminum for power electronics, EV, battery and outdoor enclosures; plastic suits low-power indoor consumer gear.
What IP rating can you achieve?
We design the groove, gasket and end sealing to the class your application needs — commonly IP54 to IP65 for extruded enclosures with gasketed ends. The exact IP rating is confirmed against your requirement and validated on samples, not assumed.
Can the enclosure be EMC shielded?
Yes. Conductive anodize or plating on mating surfaces plus a continuous seam path provides EMC shielding. Specify the test standard and level in the drawing so we design the contact surfaces and closure accordingly.
Need an enclosure built around your board?
Send the drawing — we return a DFM review covering alloy, wall, sealing, EMC and finish before tooling.