Custom Metal Enclosures and Parts for Electronics Hardware

Sheet metal fabrication, CNC machining, and die casting — from single prototype parts to production runs, integrated with PCBA assembly and plastic enclosure production.

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Precision CNC-machined aluminum enclosure with multiple machined features
Precision CNC-machined aluminum enclosure with multiple machined features

Sheet Metal

CNC Machining

Die Casting

Laser Cutting

Surface Finishing

Extrusion

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Compare Processes ↓

Aluminum · Steel · Stainless · Brass · Copper | Prototypes from 1 piece | Surface finishing included

PROCESSES

Three metal fabrication processes — which is right for your product?

Sheet metal, CNC machining, and die casting serve different product requirements, volumes, and budgets. Understanding the differences helps you specify the right process — and get an accurate quote first time.

Sheet Metal Fabrication

Sheet metal starts as flat stock — steel, aluminum, or stainless — that is laser-cut or punched to shape, then formed into 3D geometry using CNC press brakes. The result is a rigid, precise enclosure assembled with hardware, welding, or clinching.

See detailed specifications and materials for each process in our capabilities section.

  • Materials: Al, Steel, SS, Brass, Copper

  • Thickness range: 0.5mm – 6.0mm

  • Bend radius: 1× material thickness min

  • Hole tolerance: ±0.1mm typical

  • Minimum quantity: 1 piece

  • Prototype lead time: 5–8 business days

BEST FOR: Enclosures, chassis, mounting brackets, rack panels, heatsink fins, RF shielding enclosures

NOT IDEAL FOR: Complex 3D geometry, features requiring ≥3 bend operations on same face, cosmetically critical A-surfaces

See capabilities and materials ↓

CNC Machining

CNC machining removes material from a solid billet using multi-axis cutting tools — producing parts with complex internal geometry, precise dimensions, and excellent surface finish. Material is cut, not formed, so there is no tooling cost and no minimum quantity.

Die casting forces molten metal — typically aluminum or zinc alloy — into a hardened steel die under high pressure. Once solidified, the part is ejected with near-net-shape geometry. Tooling cost is significant but per-part cost at volume is very low.

  • Materials: Al 6061/7075, Steel, SS 304/316, Brass, Cu

  • Dimensional tolerance: ±0.05mm standard · ±0.02mm precision

  • Surface roughness: Ra 1.6μm standard · Ra 0.4μm precision

  • Minimum quantity: 1 piece — no tooling required

  • Prototype lead time: 5–10 business days

  • Max part size: 600 × 400 × 300mm typical

BEST FOR: Precision housings, heatsinks, structural brackets, RF cavities, prototype enclosures, small-series production

NOT IDEAL FOR: High-volume production (cost doesn't scale well), very thin-walled large parts, parts requiring undercuts accessible only from 5+ sides

Die Casting

BEST FOR: High-volume enclosures (1,000+ units), complex thin-walled geometry, integrated heat dissipation features, consumer electronics outer shells

NOT IDEAL FOR: Low volume (tooling cost not recoverable), very large parts (machine tonnage limits), materials requiring high-temperature resistance

  • Materials: Aluminium alloys (ADC12), Zinc (Zamak 3/5)

  • Dimensional tolerance: ±0.1mm typical · ±0.05mm with secondary ops

  • Wall thickness: 0.8mm – 6.0mm typical

  • Tooling cost: From $1,000 per die

  • Minimum quantity: 1,000 units (tooling amortization)

  • Production lead time: 4–6 weeks tooling · 2–3 weeks production

Many products use more than one process — a sheet metal chassis with CNC-machined mounting features, or a die-cast housing with CNC secondary operations for critical fits. Tell us what your product needs and we'll recommend the right combination.

CAPABILITIES & MATERIALS

Specifications and materials across all three processes

Detailed process specifications and material properties for sheet metal fabrication, CNC machining, and die casting — everything needed to evaluate manufacturability before submitting a design.

Sheet Metal Fabrication

LASER · PUNCH · BEND · WELD

Process and material confirmed at DFM review — before any tooling or production cost is committed.

PROCESS SPECIFICATIONS

  • Materials: Aluminum (5052, 6061) · Cold-rolled/Galvanized steel · SS 304/316 · Brass · Copper

  • Material thickness: 0.5mm – 6.0mm standard · up to 12mm for laser cutting without forming

  • Laser cutting tolerance: ±0.1mm typical · ±0.05mm precision laser

  • Punching tolerance: ±0.15mm typical

  • Bend tolerance: ±0.5° angle · ±0.3mm flange length

  • Minimum hole diameter: 1× material thickness (t)

  • Minimum bend flange: 3× material thickness (t)

  • Minimum inside bend radius: 0.5–1× material thickness (t)

  • Assembly methods: Hardware insertion · TIG/MIG weld · Clinching · Riveting

  • Max sheet size (laser): 1500 × 3000mm

  • Surface finish: Powder coat · Anodize (Al only) · Brush · Chrome plate · Zinc plate

  • IPC standard: N/A — dimensional per drawing · GD&T per ASME Y14.5

Equipment: CNC press brakes to 200 ton · Fiber laser cutting · TIG and MIG welding · Hardware insertion press

Equipment: 3-axis VMC · 4-axis index · 5-axis machining centre · CMM quality inspection

  • Materials: Al 6061-T6, 7075-T6, 2024 · Steel 1045, 4140 · SS 303, 304, 316L · Brass C360 · Copper C110 · Titanium on request

  • Standard tolerance: ±0.05mm (±0.002")

  • Precision tolerance: ±0.02mm (±0.001") for critical features

  • Surface roughness: Ra 1.6μm standard · Ra 0.8μm fine · Ra 0.4μm precision

  • Min wall thickness: 0.8mm aluminium · 1.0mm steel

  • Min internal radius: 0.5mm (depends on tool diameter)

  • Max part size: 600 × 400 × 300mm (3-axis) · 400 × 300 × 300mm (5-axis)

  • Min quantity: 1 piece — no tooling or setup charge at low volume

  • Thread types: Metric (M2–M64) · UNC/UNF · Helicoil inserts available

  • Deburring: Manual and vibratory deburring standard on all parts

  • Inspection: CMM inspection available · First article with report on request

  • GD&T: Per ASME Y14.5 · ISO 2768 fine grade standard

CNC Machining

3-AXIS · 4-AXIS · 5-AXIS

  • Aluminum alloys: ADC12 (most common) · A380 · A360 · A413

  • Zinc alloys: Zamak 3 · Zamak 5 · Zamak 7

  • Standard tolerance: ±0.1mm for non-critical · ±0.05mm with secondary CNC

  • Min wall thickness: 0.8mm aluminium · 0.4mm zinc alloy

  • Max wall thickness: 6.0mm (above this, use shrinkage precautions)

  • Draft angle: 0.5°–1° per side for cosmetic · 1°–3° for structural

  • Surface roughness: Ra 1.6–3.2μm as-cast · Ra 0.8μm with secondary machining

  • Tooling material: H13 hardened steel · P20 for lower volume

  • Shot life: H13: 500,000–1,000,000 shots · P20: 100,000–300,000

  • Secondary operations: CNC machining · Drilling · Tapping · Tumble deburring

  • Surface treatment: Shot blast · Powder coat · Paint · Chrome plate · Anodize (Al alloys only, note below)

  • Min production quantity: 1,000 units — below this, tooling cost typically not recoverable

Die Casting

AL ALLOY · ZINC ALLOY

Equipment: Die casting machines 160–800 tonne · Trim press · Shot blast · CNC secondary machining

MATERIALS

Aluminum

5052 · 6061 · 7075

  • WEIGHT: 2.7 g/cm³ — lightest structural metal

  • STRENGTH: 6061-T6: 276 MPa · 7075-T6: 503 MPa

  • CORROSION: Excellent — self-passivating oxide layer

  • MACHINABILITY: Excellent — fastest to machine

  • Process compatibility:
    Sheet ● · CNC ● · Die Cast ●

  • TYPICAL APPLICATIONS:
    Enclosures, heatsinks, chassis, RF cavities, structural brackets, prototype housings

  • WEIGHT: 7.85 g/cm³ — heavy but strong

  • STRENGTH: 1018: 440 MPa · 1045: 625 MPa

  • CORROSION: Poor uncoated — requires surface treatment

  • COST: Lowest of all structural metals

  • Process compatibility:
    Sheet ● · CNC ● · Die Cast ○

  • TYPICAL APPLICATIONS:
    Structural chassis, heavy-duty enclosures, magnetic shielding, mounting brackets

Steel

SPCC · 1018 · 1045

  • WEIGHT: 7.9 g/cm³

  • STRENGTH: 304: 515 MPa · 316: 485 MPa

  • CORROSION: Excellent — resists most acids and chlorides

  • MACHINABILITY: Moderate — harder to machine than mild steel

  • Process compatibility:
    Sheet ● · CNC ● · Die Cast ○

  • TYPICAL APPLICATIONS:
    Medical equipment housings, food-safe enclosures, marine electronics, chemical-resistant panels

Stainless Steel

304 · 316 · 316L

  • WEIGHT: 8.5 g/cm³

  • STRENGTH: C360: 385 MPa

  • CONDUCTIVITY: Good electrical and thermal conductor

  • MACHINABILITY: Excellent — free-machining C360

  • Process compatibility:
    Sheet ● · CNC ● · Die Cast ◐

  • TYPICAL APPLICATIONS:
    RF connectors, EMI shielding components, precision hardware, decorative electronics panels

Brass

C360 · C260

  • WEIGHT: 8.96 g/cm³ — heaviest common metal

  • THERMAL: 401 W/m·K — excellent heat spreader

  • CONDUCTIVITY: 100% IACS — highest electrical conductivity

  • MACHINABILITY: Good — softer than steel, work-hardens

  • Process compatibility:
    Sheet ● · CNC ● · Die Cast ○

  • TYPICAL APPLICATIONS:
    Busbars, heatspreaders, RF shielding, high-current busbars, grounding straps, EMI gaskets

Copper

C110 · C101

  • WEIGHT: 6.6 g/cm³ — lighter than steel, heavier than Al

  • STRENGTH: Zamak 3: 283 MPa · Zamak 5: 331 MPa

  • MIN WALL: 0.4mm — thinnest walls achievable

  • FLUIDITY: Excellent — fills complex features

  • Process compatibility:
    Sheet ○ · CNC ◐ · Die Cast ●

  • TYPICAL APPLICATIONS:
    Complex thin-walled housings, decorative covers, small precision enclosures, high-volume consumer electronics components

Zinc Alloy

Zamak 3 · Zamak 5

SURFACE FINISHING OPTIONS

Powder Coating
S● C● D●
Colour, corrosion protection, texture

Anodizing
S● C● D◐
Aluminium only · Hard or decorative

Brushing
S● C● D○
Satin texture · Cosmetic surfaces

Electroplating
S● C● D●
Chrome, nickel, zinc, gold

Shot Blasting
S● C● D●
Matte texture · Pre-treatment

Passivation
S● C● D○
Stainless steel · Removes free iron

Laser Engraving
S● C● D○
Permanent marking · Serial numbers

See pricing and lead times ↓

PRICING & LEAD TIMES

Realistic cost and timeline expectations

Indicative pricing ranges for sheet metal, CNC machining, and die casting — based on typical electronics enclosure complexity. Exact quotes require DXF, STEP, or DWG files.

Sheet Metal Fabrication

Most cost-effective for box enclosures — no tooling cost for laser cutting, low setup cost for bending.

Tier 1 — PROTOTYPE (1–10 PIECES):
$50 – $300 per part
Simple bracket or panel · Increases with complexity

Prototype lead time: 5–8 business days
Production lead time: 10–15 business days
Repeat order premium: None — same as first order

Get a metal parts quote →

CNC Machining

Die Casting

Tier 2 — SMALL PRODUCTION (50–500 PCS):
$15 – $80 per part
Standard enclosure · Material + forming + finishing

Tier 3 — SETUP / FORMING DIES:
$0 – $500 per part type
Laser: $0 setup · Custom punching die: $200–500

Prototype from a single piece with no tooling cost — per-part cost is higher than other processes but unmatched for complexity and precision.

Tier 1 — SIMPLE PARTS (1–5 PIECES):
$80 – $300 per part
Simple geometry · Aluminium · Standard tolerance

Tier 2 — COMPLEX PARTS (1–5 PIECES):
$300 – $1,500 per part
Multiple setups · 5-axis · Tight tolerance · Hard material

Tier 3 — VOLUME (10–100 PIECES):
20-40% reduction vs single-piece price
Setup cost amortized · Program reused · Material efficiency

Prototype lead time: 5–10 business days
Repeat order lead time: 3–7 days (program saved)
Tooling / setup cost: Included in quoted price

High tooling cost offset by very low per-part cost at volume — economical only above 1,000 units per production run.

Tier 1 — TOOLING COST (ONE-TIME):
$2,000 – $5,000 per die
Simple single-cavity: from $5,000 · Complex multi-cavity: to $25,000+

Tier 2 — PER-PART COST (1,000+ UNITS):
$2 – $15 per part
Aluminium alloy · Medium complexity · Excludes secondary ops

Tier 3 — SECONDARY OPERATIONS:
$1-$8 per part additiional
CNC machining · Drilling · Tapping · Tumble deburr

Tooling lead time: 4–6 weeks
Production lead time: 2–3 weeks (after tooling approval)
Tooling ownership: Yours — stored at our facility

What drives metal fabrication cost

WHAT INCREASES COST

  • Tight tolerances

  • Complex geometry

  • Fine surface finish

  • Low volume

  • Threaded inserts and hardware

  • Custom alloys

WHAT REDUCES COST

  • Design for process

  • Standard alloys

  • Relaxed tolerances

  • Increase volume

  • Minimise setups

  • Submit complete files first time

  • Consolidate orders

The highest single impact on cost is material and process selection — designing in 6061 aluminium for sheet metal or CNC machining rather than stainless or titanium can reduce part cost by 40–60%.

Every quote is fixed-price — the price you agree to is the price you pay. We don't add charges after the quote is accepted, and we don't bill by the hour for machining time overruns. If we underestimate the complexity of a part at quoting stage, we absorb the difference.

The ranges shown on this page are starting points based on typical electronics enclosure complexity. A simple sheet metal bracket comes in at the lower end. A complex 5-axis machined aluminium housing with tight tolerances and fine surface finish comes in higher. Your part falls somewhere on that spectrum — the quote tells you exactly where.

DFM feedback is included with every quote at no charge. If your design has features that significantly increase cost — or features that could be modified to reduce cost without affecting function — we'll flag both in the quote response.

Ready to get a fixed-price quote? Send us your STEP, DXF, or DWG files and we'll respond within 48 hours.

Tell us about your metal part

Send your DXF, STEP, or DWG files with a description of your requirements — we'll respond with a fixed-price quote within 48 hours.

GET A QUOTE

DFM review included with every quote · Fixed-price guarantee · Response within 48 hours