Aluminum Enclosures Manufacturer
CNC machined, extruded, cast, and forged aluminum enclosures for electronics. Designed and manufactured in our factory in Dongguan, China. From single prototypes to production runs.
Overview
Why Aluminum For Electronic Enclosures
Aluminum is the most widely used material for electronic enclosures because it combines four properties no other material matches at the same cost: EMI/RFI shielding (blocks electromagnetic interference without additional coatings), thermal management (conducts heat away from components 4x better than steel), low weight (one-third the density of steel), and corrosion resistance (naturally forms a protective oxide layer, further improved by anodising).
The choice of manufacturing method depends on your volume, geometry, tolerance, and budget. A CNC machined enclosure from a block of aluminum costs nothing in tooling but more per part. An extruded enclosure costs less per part but requires a die. A die-cast enclosure has the lowest per-part cost at high volumes but the highest tooling investment. In all cases, Davantech handles the precision CNC machining that turns a raw blank into a finished enclosure with tight tolerances, threaded features, and custom cutouts.
FUll CNC MACHINING
Solid aluminum blocks milled to precision. No tooling investment, no minimum order. Tight tolerances (±0.05 mm or better), complex geometries, and superior surface quality. Design changes are a CAD file update. The fastest route from drawing to finished part.
- Low-to-medium volume (1 – 500 pcs)
- Medical, aerospace, and defence electronics
- Complex internal features, thin walls, tight fits
- Alloys: 6061-T6, 7075-T6
- Can be Anodized
EXTRUDED + CNC MACHINING
Aluminum pushed through an extrusion die creates the cross-sectional profile. Our CNC machines then cut the enclosure to length and add all precision features: connector cutouts, mounting holes, threaded bosses, ventilation slots. Cost-effective for medium to large runs with excellent heat dissipation.
- LED drivers, power supplies, IoT devices
- Split-body or single-body profiles
- Medium to high volume (100 – 10,000+ pcs)
- Alloys: 6063, 6060, 6061
- Can be Anodized
DIE CAST + CNC MACHINING
Molten aluminum injected into a mold creates the complex shell with integrated ribs, bosses, and cable entries. Our CNC machines then finish the critical interfaces: mating surfaces, O-ring grooves, threaded holes, and precision bores that casting alone cannot achieve.
- Outdoor junction boxes, telecom housings
- Automotive and ruggedised electronics
- High volume production (1,000 – 100,000+ pcs)
- Alloys: ADC12/A380, AlSi10Mg
- Can Not be Anodized
FORGED + CNC MACHINING
Aluminum billets forged under high pressure to align the grain structure for exceptional strength. Our CNC machines then bring the forging to final dimensions with tight tolerances. The strongest option, designed for shock, vibration, and extreme environments.
- Military and aerospace housings
- Rugged outdoor and offshore equipment
- Economical above 3,000 pieces
- Alloys: 6061, 7075 (forged)
- Can be Anodized
Enclosure Type Comparison
Choosing the right manufacturing method depends on your volume, precision needs, geometry complexity, and budget. This table summarises the trade-offs.
| Factor | CNC from Billet | Extruded + CNC | Die Cast + CNC | Forged + CNC |
|---|---|---|---|---|
| Tooling cost | None | $1,000 - $5,000 | $5,000 - $30,000 | $10,000 - $50,000 |
| Best volume | 1 - 500 pcs | 100 - 10,000+ | 1,000 - 100,000+ | 3,000 - 50,000+ |
| Final tolerance | ±0.05 mm | ±0.05 mm (machined features) | ±0.05 mm (machined features) | ±0.05 mm (machined features) |
| Geometry complexity | High | Low (constant profile) | High | Medium |
| Wall thickness | ≥ 1.0 mm | ≥ 1.0 mm | ≥ 1.5 mm | ≥ 2.0 mm |
| Strength | Good | Good | Good | Excellent |
| Lead time (first part) | 5 - 7 days | 2 - 4 weeks (die) | 6 - 10 weeks (mold) | 4 - 8 weeks (die) |
| Design changes | Update CAD file | New extrusion die | Modify or remake mold | Modify or remake die |
| CNC machining role | Entire part | Cutouts, holes, threads, faces | Interfaces, bores, O-ring grooves | Final dimensions, all features |
Not sure which method is right? Send us your 3D model and requirements. We'll recommend the most cost-effective manufacturing route and provide a quote for each viable option. See our 5 ways to fabricate aluminum parts for a deeper comparison.
Industries We Serve with Aluminum Enclosures
- PLC and controller housings
- Sensor enclosures
- Motor driver casings
- DIN rail mount boxes
- 5G radio enclosures
- Network switch housings
- RF shielded boxes
- Outdoor antenna mounts
- Diagnostic instrument housings
- Portable monitor cases
- Sterilisable enclosures
- Lab equipment chassis
- LED driver enclosures
- Power supply housings
- Battery management boxes
- Inverter chassis
- ECU housings
- EV charging controller boxes
- On-board charger enclosures
- ADAS sensor housings
- Gateway enclosures
- Edge computing boxes
- Outdoor IP-rated housings
- Compact consumer electronics
Design guide
Enclosure Design Considerations
Getting the enclosure design right before manufacturing saves time and money. These are the factors we review during every DFM assessment.
Aluminum provides inherent shielding, but effectiveness depends on joint design, gasket selection, and surface conductivity. Anodising reduces conductivity at contact surfaces; use conductive chromate conversion or leave mating surfaces bare.
IP65 and IP67 enclosures require O-ring grooves machined into the mating surfaces, proper compression ratios, and gasketed cable entries. We design the O-ring groove geometry as part of the DFM review.
Aluminum conducts heat at 167 W/m·K. Fins, heat pipes, and thermal pads can be integrated into the enclosure design. Wall thickness and airflow paths affect cooling performance.
Anodising (Type II for cosmetics, Type III hard anodise for wear resistance), powder coating for colour matching, bead-blast for matte finish, brushing for directional texture. Each treatment adds 5-25 µm to dimensions.
Standoffs, card guides, heat sink bosses, and cable management features can be machined directly into the enclosure. Define PCB dimensions and mounting pattern early so the enclosure design integrates them.
19-inch rack modules (1U, 2U, 3U), 24-inch rack, NEMA ratings, or custom dimensions. We design to your standard or help you choose the right form factor for your application.
Read our design guidelines for machined parts for detailed DFM rules including wall thickness, corner radii, and tolerancing best practices.
Why Davantech?
Why Order Enclosures From Davantech
CNC machining, extrusion sourcing, die casting, forging, surface treatment, and final assembly. One supplier, one quality system, one shipment.
Belgian engineering leadership in Dongguan. Direct communication in English, European quality standards, Chinese factory pricing.
We provide 3D modelling, DFM review, and manufacturing route recommendation with every quote. Send us a sketch or concept and we’ll develop it into a production-ready design.
No minimum order. Prototypes in 5-7 days. Production runs with consistent quality under ISO 9001:2015.
Aluminum Enclosure Questions
Which aluminum alloy is best for electronic enclosures?
6061-T6 is the most common choice for CNC machined enclosures. It offers good strength, excellent machinability, and is compatible with anodising. 6063 is preferred for extruded enclosures because of its superior extrudability and smooth surface finish. For die casting, ADC12 (A380) is standard. For high-strength applications (military, offshore), 7075-T6 or forged 6061 may be appropriate.
What is the minimum wall thickness for an aluminum enclosure?
For CNC machined enclosures: 1.0 mm minimum, 1.5 mm recommended for structural rigidity. For die cast: 1.5 mm minimum. For forged: 2.0 mm minimum. Thinner walls increase machining difficulty and risk of distortion. If EMI shielding is required, thicker walls (≥ 2.0 mm) improve shielding effectiveness.
Can you manufacture IP67-rated aluminum enclosures?
Yes. IP67 requires complete dust protection and temporary immersion resistance. We achieve this by machining O-ring grooves into the mating surfaces of the enclosure halves, using properly sized O-rings (typically silicone or EPDM), and sealing all cable entries with IP-rated glands or overmolded connectors. The O-ring groove dimensions and compression ratio are part of our DFM review.
How do you ensure EMI/RFI shielding in aluminum enclosures?
Aluminum itself is an excellent EMI shield. The weak points are joints, seams, and openings. We ensure shielding effectiveness by designing close-tolerance mating surfaces, adding EMI gaskets or conductive elastomer seals where needed, and recommending chromate conversion coating (instead of anodising) on contact surfaces to maintain electrical conductivity.
What surface finishes are available for aluminum enclosures?
Anodising Type II (cosmetic colours, 5-25 µm), hard anodising Type III (wear resistant, 25-75 µm), powder coating (any RAL colour), chromate conversion (conductive, corrosion resistant), bead-blasting (matte texture), brushing (directional grain), and polishing (mirror finish). Multiple finishes can be combined on one part. See our surface treatment options.
Can you design the enclosure or do I need to provide a finished CAD model?
Both. If you have a finished 3D model, send it and we'll quote directly. If you have a concept, sketch, or PCB dimensions, our engineering team can develop the enclosure design from scratch including 3D modelling, DFM review, and manufacturing route recommendation. Design support is included in the project, not charged separately.
What is the lead time for custom aluminum enclosures?
CNC machined prototypes: 5-7 working days. Extrusion (with new die): 2-4 weeks. Die casting (with new mold): 6-10 weeks. Forging (with new die): 4-8 weeks. Production runs after tooling: 2-4 weeks. Air freight shipping adds 3-5 days door to door.
Do you manufacture 19-inch rack enclosures?
Yes. We manufacture 19-inch and 24-inch rack-mount enclosures in standard heights (1U, 2U, 3U, 4U) and custom dimensions. These can be CNC machined from billet for low volumes or produced from extruded profiles with CNC-machined features for larger runs. See our 19-inch rack module page.
Get your electronic enclosures quoted today.
Send your 3D model, sketch, or specifications. We return a detailed quote with DFM review, manufacturing route recommendation, and lead time within 24 hours.