ENCLOSURES
Transforming Standard Aluminium Enclosures: The Power of Customisation
METCASE’s customising services can transform both the inside and outside of its aluminium enclosures
I
t does not take much customisation to make a standard aluminium enclosure look unique. Judicious use of custom colours and photo-quality digital printing can transform off-the-shelf 19” rack cases and desktop instrument housings.
Most customisation tends to focus on the front and rear panels which, being flat, are easy to machine and finish. The exterior is only half the story. Much of the customisation magic happens inside.
The interior is the part of the enclosure that the end-user never sees, but it is where electronics designers face the challenge of finalising component layout and ensuring that everything fits.
Internal customisation options include the fabrication of special plates. These enable the secure mounting of a power supply, assemblies and fan units, which in turn are also likely to require corresponding ventilation slots in the outer casing.
Good design advice from an enclosures manufacturer can be invaluable, providing smart and cost-effective solutions to issues involving component placement, heat dissipation and vibration. Custom internal fittings can also simplify the assembly process by providing clearly predefined mounting points, reducing installation times and minimising the risk of errors.
Even though many modern aluminium enclosures are manufactured with an earth stud on every panel as standard, customised enclosures typically still need a wide range of other fixings and inserts: standoffs, self-clinch nuts, right-angle panel nuts and cable-tie mounts.
Through standoffs are designed to provide a threaded hole all the way through the metal. They are used when components need to be secured from both sides of the panel. Their main advantage is strength.
Blind standoffs have a threaded hole that does not go all the way through the material. They are ideal for applications in which a clean and sealed surface must be maintained on one side of the panel. Their primary benefit is that they prevent contaminants from entering, but they may not be as strong as
through standoffs due to their lack of through-hole support.
Concealed-head standoffs leave a smooth and aesthetically pleasing surface on the outside of the enclosure. They are often used in applications where appearance is important. The downside is that they may require more precise machining. PCB standoffs support circuit boards and create space between them. This helps to prevent electrical short circuits, improves heat dissipation and assists in the organisation of components. However, PCB standoffs may not be suitable for applications requiring high mechanical strength.
Self-clinch nuts are pressed into a pre-punched hole, providing strong threads. Installation is quick and efficient and, unlike welded fasteners, self-clinch nuts do not produce weld splatter. Both the panel and the fastener can be pre-finished, reducing the need for post-installation finishing. Right-angle panel nuts help to optimise the use of space within the enclosure by allowing
components to be mounted in a way that maximises available capacity. Installing these nuts can be more complex, compared with other types of fasteners, but this won’t be an issue for an experienced enclosures specialist. Cable-tie mounts are quick and easy to install, making them a cost-effective way to secure wiring in position. Aside from organising cables neatly, these mounts can save space. This can be crucial in ensuring that designers specify the smallest enclosure possible for their device.
METCASE marketing director Robert Cox said, “Getting extra advice on internal plates, fixings and inserts can be crucial in making everything fit. In that respect, they can have a surprisingly large impact on the finished product.
“Saving a little space may be all it takes to help a designer specify the next size down or to specify an off-the-shelf enclosure instead of a larger bespoke size. This can help to cut costs,” he added.
OCTOBER 2024 | ELECTRONICS FOR ENGINEERS
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