A leading electrical equipment provider needed indoor and outdoor junction boxes that seal out water, dust and UV across thousands of sites. We delivered 6,000 IP65-rated galvanized steel enclosures with precision-milled sealing grooves and dual-environment powder coating.
Precision-engineered indoor and outdoor electrical junction boxes built to your exact specifications
From initial concept to final delivery –every detail of this custom fabrication project
Industrial electrical systems and outdoor infrastructure keep expanding –distribution boxes sit inside clean distribution rooms, on factory walls, and on poles and posts exposed to rain, sun and dust. In 2026, a leading electrical equipment provider launched a large-scale program for a single junction box family that had to perform reliably in both indoor and outdoor settings.
The enclosure protects wiring terminals, control modules and circuit components, so any water or dust ingress is a direct field-failure and safety risk. IP65 was a non-negotiable requirement.
The customer’s previous supplier could not hold a consistent seal at volume:
We faced four hard challenges:
We rebuilt the sealing system from the groove outward. Precision-milled sealing grooves, high-precision CNC bending and custom-molded waterproof silicone gaskets work together, and every unit passes an online air-integrity seal test before it leaves the line.
The 6,000-unit order shipped 5 days ahead of the 45-day schedule and passed 100% of dimensional, IP65, salt-spray and coating adhesion tests.
For six thousand units, the seal never failed a single rain test. The indoor and outdoor finishes are both exactly to spec, and our installers report the boxes go together without shimming. SanJun Hardware is now our exclusive sheet metal supplier for the entire junction box series.
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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