We produced 500 outdoor enclosures for 480kW ultra-high-voltage EV charging piles on a salt-spray-prone coastal highway network. The 316 stainless cabinets resist 1,500-hour salt spray, hold 0.1mm flatness for power modules, and weigh just 35kg for quick field installation.
Precision-engineered outdoor new energy charging infrastructure built to your exact specifications
From initial concept to final delivery –every detail of this custom fabrication project
Driven by the push for green mobility, a leading East China EV charging operator launched a coastal highway ultra-fast charging network. It needed 500 enclosures for 480kW ultra-high-voltage charging piles installed across salt-spray-exposed coastal service areas.
The housings had to fight coastal chloride corrosion, stay dead-flat for high-power electronics, remain light enough for field crews, and seal reliably against dust and rain.
Coastal UHV charging is unforgiving on sheet metal:
Five constraints had to be solved together:
We upgraded the outer cabinet from 304 to molybdenum-bearing 316 stainless and added post-weld passivation, passing a 1,500-hour salt-spray test. Raw sheets were leveled to +/-0.02mm/m before forming, then CMM-inspected per unit to keep flatness at or under 0.1mm.
6061-T6 aluminum brackets with laser-welded ribs cut weight from 41kg to 35kg while FEA validated the cabinet against 500N wind loads. The air-spring door was laser-cut to +/-0.03mm, with a 0.2mm gasket recess and 0.05mm-step hinges calibrated to an average 0.25mm gap. Robotic loading and 10% batch CMM checks kept all 500 units identical.
The full 500-unit order completed in 28 days, inside the 30-day deadline, with a 100% pre-delivery pass rate.
After 12 months of coastal service, the piles showed zero visible corrosion or coating peeling, flatness held under 0.08mm, and the air-spring doors cycled smoothly with IP54 intact. The operator renewed for 800 more units.
Sanjun’s precision craftsmanship and truly scalable customization let us roll out a 480kW coastal network without a single corrosion or alignment failure.
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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