We engineered ultra-compact sheet metal enclosures that house the power supply modules, circuit boards and wiring inside next-generation 5G and IoT communication devices. At just 8.8 x 4.2 x 2.5 cm, each box pairs a 0.8 mm galvanized-steel shell, precision interface cutouts and a durable matte-black finish. The run of 470 units shipped three days ahead of schedule and grew into a two-year exclusive supply agreement.
Precision-engineered compact telecom power box enclosures built to your exact specifications
From initial concept to final delivery –every detail of this custom fabrication project
As 5G and IoT rollouts keep accelerating, a leading telecom equipment manufacturer launched a 2026 program for a new family of miniaturized power box enclosures. Each housing had to protect sensitive power modules and circuit boards while surviving years of unattended, long-term operation.
The customer had been burned by two recurring issues on such a tiny part: housings that deformed during bending, and interface ports that drifted out of alignment and failed their assembly test. On top of that, the matte-black color varied between batches, which was unacceptable for a visible telecom product.
The core engineering problem was getting structural strength out of a 0.8 mm shell that is only 25 mm tall. Every extra stiffener threatened the weight and envelope the customer had specified, while dozens of micro cutouts demanded near-zero thermal distortion from the laser cutting process.
We reworked the internal architecture with integrated snap-fit reinforcing ribs, raising rigidity by about 20 percent at no extra weight. A 6000 W fiber laser running nitrogen assist produces clean, burr-free micro cuts, and CNC micro-punching with real-time calibration locates every port. Crucially, first-article samples were assembled on the customer’s own power modules to lock in the fit before any mass production began.
The first 470 units passed CMM dimensional inspection, cross-hatch coating tests and interface fit checks with a 100 percent pass rate, and shipped three days ahead of the 25-day plan. Across six months of field testing in telecom environments there was no deformation, fit problem or coating wear. The customer then signed a two-year exclusive supply agreement covering the entire compact power module line.
Sanjun solved two problems our previous vendors could not: a rigid housing at an impossible 25 mm profile, and a truly consistent matte-black finish. The first article already fit our power modules perfectly, and delivery was early. They are now our exclusive enclosure partner.
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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