We designed lightweight rack-mounted enclosures in 1.5 mm aluminum alloy to house the core control modules and interface boards inside industrial automation and data-center equipment. At 44 x 43.5 x 4.2 cm, each unit combines dual-sided honeycomb ventilation, integrated rack ears and a clear anodized finish. The 400-unit run shipped three days early and cut rack load by roughly 30 percent versus a steel alternative.
Precision-engineered rack-mounted multi-function control box enclosures built to your exact specifications
From initial concept to final delivery –every detail of this custom fabrication project
With industrial automation and data-center build-outs expanding, a leading industrial control equipment manufacturer launched a 2026 program for rack-mounted multi-function control box enclosures. The housings had to protect core control modules and interface boards while staying light enough to ease rack loading and tough enough for 24/7 operation.
The customer wanted to replace heavier steel enclosures to reduce rack weight, but aluminum presented its own challenges: the slim chassis had to stay rigid under heavy control modules, and the modular interior with dozens of mounting studs and slots had to line up precisely. Anodizing also had to look perfectly consistent across a 400-unit aluminum run.
Aluminum bends differently than steel, so controlling springback and keeping a 42 mm-deep chassis flat under heavy modules demanded dedicated jigs. Dual-sided honeycomb panels had to maximize airflow without weakening the structure, and the anodizing line had to deliver a uniform clear finish on every one of 400 units.
We optimized the interior with integrated support brackets and partition plates, lifting rigidity by about 28 percent at no added weight. A 12000 W fiber laser and CNC punching with live calibration locate every mounting stud and slot, while dual-sided honeycomb panels maximize airflow. A standardized anodizing line with strict temperature control and sampling every 20 units keeps the finish uniform. First-article units were assembled with the customer’s control modules before mass production.
The 400 units passed CMM inspection, adhesion testing, full-load thermal imaging and rack compatibility checks with a 100 percent pass rate, shipping three days ahead of the 30-day plan. In data-center field testing over six months there was no overheating, deformation or fit issue, and the aluminum design cut rack load by about 30 percent versus the previous steel enclosures. The customer signed a two-year exclusive supply agreement.
Switching to Sanjun’s aluminum chassis cut the weight per rack by nearly a third, and the dual-sided honeycomb design kept our controllers cool even at full load. The anodize is identical on every unit. This is exactly the kind of dependable supply we wanted for a long-term program.
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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