Project Background
With the rapid expansion of edge computing and small-scale data centers, a leading IT infrastructure manufacturer launched a large-scale customization project in 2026 for wall-mounted server cabinet enclosures. These enclosures are critical for protecting server hardware, network switches, and power modules in space-constrained environments, requiring stable performance in both office and industrial settings.
Key requirements included:
- IP54 dust and water resistance
- Dimensional tolerance ≤±0.03mm
- Efficient heat dissipation for continuous operation
- Lightweight design for secure wall mounting
- Compatibility with standard 19-inch rack equipment
- Stable mass production quality
- Durable surface finishes for long-term use
Sanjun Hardware was selected for its precision sheet metal technology, professional heat dissipation design, and proven track record in industrial enclosure customization.
Manufacturing Process of Core Components
The wall-mounted server cabinet consists of the main enclosure, front door panel, side ventilation panels, and mounting brackets. All production follows ISO 9001 quality standards and industrial server enclosure specifications.
1. Material Selection & Pre-treatment
- Main enclosure & panels: 1.2mm cold-rolled galvanized steel sheet, providing high structural strength and basic corrosion resistance.
- Pre-treatment: Fully automated ultrasonic degreasing, derusting, and phosphating to create a clean, high-adhesion surface base ideal for electrostatic powder coating.
2. Core Manufacturing Craftsmanship
- Precision Laser Cutting: 8000W fiber laser cutter with ±0.02mm tolerance, using nitrogen assist gas to minimize heat distortion and maintain material integrity.
- CNC Bending & Forming: 9-axis CNC bending machine with custom jigs, ensuring springback ≤0.02mm and consistent structural dimensions.
- Heat Dissipation Structure: Precision-punched ventilation grilles and fan mounting holes on the side panels, designed to optimize airflow and maintain optimal operating temperatures.
- Electrostatic Powder Coating
- Assembly & Sealing: High-density foam gaskets embedded in the front door frame to ensure a tight seal. Heavy-duty mounting brackets with reinforced welds are integrated into the enclosure for secure wall installation.
3. Quality Control & Testing
- Dimensional inspection: CMM measurement to confirm tolerance ≤±0.03mm and compatibility with 19-inch rack equipment.
- IP54 protection test: Dust and water resistance testing per IEC 60529 standards.
- Heat dissipation test: Thermal imaging to verify efficient airflow and temperature control under full load.
- Load-bearing test: Static load testing of mounting brackets to ensure safe support for server hardware.
- Full functional inspection: 100% inspection before delivery for zero defects.
Project Challenges & Solutions
1. Challenge: Balancing Heat Dissipation and Dust Protection
The server cabinet requires efficient airflow to prevent overheating, while also needing to protect internal components from dust and debris.
Solution: We designed a multi-layer ventilation system with precision-punched grilles and removable dust filters, allowing for optimal airflow while preventing dust ingress. Each enclosure undergoes airflow testing to ensure performance meets specifications.
2. Challenge: Lightweight Design for Wall Mounting
The enclosure must be lightweight for easy installation, yet strong enough to support heavy server hardware.
Solution: Through finite element analysis (FEA), we optimized the internal structure with lightweight reinforcing ribs, improving structural strength by 20% without increasing the overall weight.
3. Challenge: High Consistency in Batch Customization
The customer required 400 units with uniform appearance, size, and performance across all batches.
Solution: Automated production lines and Statistical Process Control (SPC) are used to monitor processing parameters in real time. Sampling inspection is carried out per 50 units to ensure stability of size, surface finish, and functional performance.
4. Challenge: Compatibility with Standard Rack Equipment
The enclosure must seamlessly accommodate standard 19-inch server hardware and network equipment.
Solution: We used laser positioning technology to ensure the accuracy of mounting rails and equipment slots within ±0.01mm. Pre-production sample assembly was conducted with the client’s hardware to verify compatibility before mass production.
Project Outcomes
- Delivery: 400 units completed and delivered 6 days ahead of the 50-day schedule, with a 100% pass rate in all tests.
- Performance: Enclosures operate stably in both office and industrial environments, with no overheating, dust accumulation, or structural issues reported.
- Partnership: The client signed a 3-year strategic cooperation agreement, appointing Sanjun Hardware as the exclusive sheet metal enclosure supplier for its full line of wall-mounted server cabinets.
