Aluminum is everywhere we look around us today—from our handheld devices to automobile and airplane parts. Across the business world and beyond, one form of aluminum has gained particular popularity for OEM manufacturing: extruded aluminum electronics enclosures. Polycase’s EX Series of enclosures are some of the most popular. So, what is it that makes them such an outstanding choice?

Use an Aluminum Enclosure That Is Affordable Yet Durable

Extruded aluminum’s use is on the rise in electronics manufacturing, thanks to its perfect fusion of durable performance, cost-effectiveness and aesthetic appeal. We’ll look at the properties that make this material special, why our customers at Polycase love it and six common applications for it.

Polycase EX-57 Extruded Aluminum Enclosure

Polycase EX-57 Extruded Aluminum Enclosure

The Basics of Aluminum and Aluminum Extrusion

Aluminum has applications in numerous industries, thanks to its unique combination of properties that make it an ideal material choice for a metal enclosure. Some of its most desirable characteristics include:

  • More resistant to corrosion than other common metals, such as mild steel
  • Extremely light, but relatively durable
  • Aesthetically attractive and accepts many common finishes for a variety of looks
  • Non-magnetic
  • Non-combustible and heat-resistant
  • Provides natural RFI and EMI shielding against interference

Aluminum enclosure manufacturing typically uses one of two forming processes: extrusion or die casting. Diecast aluminum enclosures are also a great choice for electronics applications, but today we’ll focus on extrusion.

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The aluminum extrusion process is a commonly used way of molding aluminum into a desired shape. Heat-softened aluminum is pushed through a die to mold it, often into a T-bar, pipe or, in our case, components for an electronics enclosure. It’s a versatile and reliable method for creating the durable, precision-molded enclosures Polycase is known for.

Polycase’s EX Series of extruded aluminum enclosures are popular among businesses, universities and hobbyists alike for their high-performance construction and design. With an IP66 rating, thanks to waterproof gasketing, they’re highly resistant to dust and water splashing. They even include a built-in slot that allows printed circuit boards to slide directly into the box without modifications.

These features make them ideal for many different applications. Take a look at just a few things our customers do with these amazing enclosures:

1. Hard Drives

Hard drives frequently contain critical data, so they need durable protection that can survive not just everyday falls and bumps, but potential water damage and high temperatures. At the same time, they’re often used in professional settings that require an elegant, understated look—a specialty of extruded aluminum. That ideal balance of aesthetics and professional-grade protection is the hallmark of the Polycase EX Series.

external backup disk laptop

2. Audio Equipment

Anyone with a high-performance audio setup knows extruded aluminum enclosures often protect some of the most essential equipment. From direct injection boxes to stereo receivers to rack-mounted audio effects, these enclosures form the backbone of numerous professional and hobbyist audio configurations.

Polycase’s aluminum enclosures are also great project boxes for DIY music gear. Their RFI and EMI shielding is ideal for protecting effects units and other devices sensitive to interference, and their sleek appearance makes your gear look great.

3. Medical Devices

You’ll often find devices medical professionals use to monitor patient vital signs and other important data enclosed in extruded aluminum enclosures. This is partially due to its electromagnetic shielding properties which helps defend medical devices against potentially dangerous RFI and EMI interference. However, it also illustrates another great benefit of aluminum: its antiseptic and easy-to-clean surfaces which can be a great fit for medical devices that must be cleaned after each use.

4. Machinery Control Panels

Control panels for industrial machinery need sophisticated, high-performance enclosures and Polycase’s extruded aluminum models are up to the challenge. Their resistance to dust, water, heat and other hazards is key for ensuring safe and effective equipment operation.

Our industrial customers also love Polycase’s custom CNC machining available for our aluminum enclosure models. Polycase’s state-of-the-art CNC machining equipment can modify an extruded aluminum enclosure with all of the custom cutouts you need, with a hyper-precise tolerance of just 0.005 inches.

5. Junction Boxes

Extruded aluminum enclosures can also serve as the junction boxes that protect our electrical infrastructure. The water and dust resistance offered by the EX Series’ gasketed, IP66-rated design is critical for protecting sensitive electrical components and keeping power flowing when it’s most important. The IP66 rating also signifies they’re suitable for both indoor and outdoor use. Lastly, they’re available with optional mounting flanges and removable end caps for an incredibly easy junction box solution.

6. New Technologies

As technological innovation continues to shape the 21st century business and scientific environment, we’ll need enclosures that meet the performance specs required for new technological applications. Extruded aluminum enclosures have the versatility, durability and style that makes them perfect for groundbreaking technologies and ensure they’ll remain relevant to the technological landscape for years to come.

Some of the properties that make the Polycase EX Series a great choice for innovative technologies include:

Polycase EX-66 with removable end caps

Polycase EX-66 with removable end caps disassembled.

Naturally, the applications don’t end there! Polycase’s extruded aluminum enclosures have a successful track record in numerous commercial, research and hobby projects and our customers use them every day to innovate and excel. If you have questions about if an aluminum enclosure is right for your project, our enclosure experts are happy to help. Just call 1-800-248-1233 or contact us online and we’ll help you get started!

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