If you’re considering an aluminum enclosure for your next project, you’re probably aware of the many benefits this metal can provide. But did you also know that the metal shaping technique of an aluminum enclosure can influence its uses and benefits?Diecasting and extrusion are two commonly used metal shaping techniques that must be taken into consideration before choosing an aluminum enclosure. In this post, we’ll discuss the pros and cons of each method to ensure that you choose the right aluminum enclosure for your application.

Diecast Aluminum Enclosure

Diecast Aluminum Enclosures

Diecasting is a popular metal manufacturing process that involves forcing molten metal into a closed mold (also called a die) to produce the desired shapes. When the material inside the mold cools, the mold is opened and the diecast is ejected.ApplicationsGiven its many desirable characteristics, aluminum alloy is a common choice for high pressure die casting. Blending aluminum with other metals can enhance specific material properties such as strength and ductility, making it suitable for a wide range of indoor and outdoor applications.For instance, diecast aluminum enclosures are often used to protect switchboards and meter cases in various industrial environments. With their natural level of RFI/EMI shielding, diecast aluminum enclosures can also be found in many healthcare instruments, where eliminating EMI/RFI interference is critical.AdvantagesWith molten metal forming the exact shape of the die, the diecasting process is ideal for those who require complex parts. Another key advantage to diecasting is that it results in thinner, lighter walls. Unlike the extrusion manufacturing process, a thick product isn’t needed to undergo diecasting. The result is a thin, lightweight aluminum enclosure with an attractive surface finish.DisadvantagesIts corrosion-resistance and EMI shielding properties make diecast aluminum enclosures a popular choice among design engineers. However, there are some disadvantages to this manufacturing technique.With its high upfront cost, diecasting is more suitable for high-volume production. Porosity is another common problem associated with diecasting and is the result of air entrapment in the metal die.Extruded Aluminum Enclosure

Extruded Aluminum Enclosures

The extrusion process involves putting aluminum into an extrusion press, where it is then forced through a die by a hydraulic ram. The result is a long part which can then be cut or machined as needed.ApplicationsBuilt to withstand a degree of dust and water, extruded aluminum enclosures can be found in both indoor and outdoor applications. Most commonly, they are found in data systems, sensors, the Internet of Things, medical applications and a wide range of information systems to protect PCBs.AdvantagesExtruded aluminum enclosures offer a variety of benefits for engineers.In addition, many extruded aluminum enclosures offer features which can help protect from all sorts of environmental factors. For example, our EX Series of extruded aluminum enclosures offer EMI protection, waterproof gaskets and are designed to meet NEMA 4x enclosures requirements.Extruded aluminum enclosures also make installation faster because the PCBs can easily slide into place. With excellent heat dissipating properties, extruded aluminum enclosures ensure that high temperatures won’t damage your sensitive PCB components.DisadvantagesThe downside of the extrusion process is that it can produce a limited number of shapes and there are some constraints on assembly methods. Additionally, the end caps must be manufactured separately.

Aluminum Enclosures

The great thing about choosing between diecast and extruded aluminum enclosures is that both offer superior benefits compared to other materials. Aluminum enclosures are incredibly durable, corrosion-resistant, lightweight and able to withstand a bevy of harsh environments.Aluminum enclosures are also environmentally-friendly and can be easily modified to meet the needs of your specific application. These features alone make aluminum—both diecast and extruded—an ideal choice for many design engineers.

Let Us Help

At Polycase, it’s our job to ensure that you choose the ideal aluminum enclosure for your unique application. The manufacturing process plays a critical role in your choice of an electronic enclosure.Both extruded and diecast offer their own unique set of benefits. If you have questions, get in touch with us! We’ll help you find the right enclosure to meet your electronic design needs.
In Aluminum Enclosures