A leading energy storage device maker commissioned 5,000 sets of portable power-supply enclosures that had to be light enough to carry, tough enough to survive outdoor use, and sealed to IP67. Sanjun engineered a 5052 aluminum body with a 304 stainless panel package and an integrated sealed cooling design.
Precision-engineered sheet metal enclosures for energy storage power supplies built to your exact specifications
From initial concept to final delivery –every detail of this custom fabrication project
With renewable energy and portable power booming worldwide, a well-known energy storage manufacturer launched a 2026 program for a new line of portable power stations. The enclosure had to protect batteries, circuit boards and cooling modules while staying light, sealing to IP67 and fitting a modular internal layout.
The core brief demanded strict dimensional precision, IP67 protection, impact resistance and compatibility with modular assembly.
Portable power sits in a hard spot: it must be light enough to carry, strong enough to carry the weight of the cells, sealed against dust and water, yet still breathe to shed heat.
The central tension was sealing against heat. A fully sealed box traps battery and electronics heat, while open vents break the IP67 rating. Thin sheet deforms under cell weight, and thick sheet kills portability.
Sanjun combined a 10000W fiber laser, a 12-axis press brake and an automated electrostatic coating line into one sealed cooling solution. The aluminum body gained FEA-designed internal ribs, cutting overall weight by 20%, while the rear panel received waterproof breathable valves and angled ventilation holes that lifted cooling efficiency by 30% without breaking IP67.
Laser-positioned assembly holes hold +/-0.01mm, and snap-in plus screw-fixed detachable panels let the client service internal modules quickly. SPC monitoring keeps every batch consistent.
All 5,000 sets shipped seven days ahead of the 50-day deadline with a 100% pass rate across CMM, IP67, drop and impact, and thermal cycling tests.
After six months in the field, the client reported a 28% drop in enclosure-related maintenance calls and a 15% gain in market share, then signed a four-year partnership covering all new energy storage lines.
Sanjun solved the sealing-versus-cooling problem that two previous suppliers could not. The enclosures are lighter, IP67 certified out of the box, and the 5,000 units all look and measure the same.
Eight reasons global brands partner with SanJun Hardware for precision sheet metal fabrication
Quality-managed production with documented processes and full traceability at every stage.
Streamlined scheduling and capacity planning ensure your orders ship when promised.
Expert design-for-manufacturing review at no cost –optimize your design before production.
Sheet metal ±0.1mm and CNC machining ±0.01mm –consistent accuracy across every batch.
From laser cutting and bending to welding, coating and assembly –all under one roof.
CMM inspection, coating adhesion tests, and 100% final inspection before every shipment.
Prototypes from 1 unit to production runs of 10,000+ –scalable capacity to match your needs.
Work directly with our engineering team –fast responses, clear updates, no middlemen.
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