Aluminum Enclosures vs. Plastic Enclosures: Determining the Right Material

When engineering a project, even the most mundane details must be considered to ensure a successful design. Of course, the dimensions of an enclosure are very important, but choosing the right material for the application can be equally important. Engineers must consider the conditions an enclosure will operate under, in addition to the obvious project costs and aesthetic requirements.We offer great options in a number of materials, including various metals and plastics. Our most popular enclosures are made of either aluminum or plastic (both polycarbonate and ABS). Many people are under the impression that aluminum is automatically more durable than plastic, but plastic enclosures can be used in similar industrial and harsh environments. However, while both materials offer industry-leading durability, there are some pros and cons to consider when determining which material and enclosure to choose.

Aluminum Enclosures

Aluminum enclosures are extremely durable. Our diecast aluminum enclosures use high quality #ADC-12 aluminum alloy casting metal, which holds its shape and stays rigid under considerable force. Aluminum is a highly conductive metal, making it a great conductor of electricity as well. In most conditions, aluminum isn’t reactive to magnetic force, either. These qualities mean it makes an excellent shield against electromagnetic frequency (EMF) and radio frequency interference (RFI). Enclosures made of aluminum can be an effective part of a project that requires independent circuitry and minimal interference.Because aluminum alloys are naturally resistant to corrosion, these enclosures can be a good choice in applications that are affected by moisture. We offer a number of finishes, including natural aluminum, powder coating or a black anodized finish. With diecasting, there are no seams or folds, other than where the body of the enclosure and the cover meet. Aluminum also offers a measure of protection against open-flame high heat. However, aluminum is thermally conductive, so it may not be the right fit for projects with temperature sensitive electronics.

Benefits of Aluminum Enclosures Include:

• Ability to withstands high temperature
• Overall ruggedness: high impact, high tensile strength, rigid
• Resistant to rusting corrosion
• Lightweight, as compared to steel
• Blocks passage of radio waves (naturally RFI shielded)
• Built-in flame protection
• UV resistant without additives
• Easy to paint and/or coat
• Does not swell or deform
• Scrap is recyclable and valuable

Plastic

Plastic is a popular engineering material that offers numerous benefits. One major benefit is that plastic does not conduct electricity. This is important when electrical shortages are a concern, providing a level of protection to the user as well.If cost is a factor, plastic is typically less expensive than metal. Plastic also weighs less than metal, which saves on transportation costs. Plastic is corrosion resistant and doesn’t need additional coating like steel or other types of metal.Plastic allows RFI and EMF waves to pass through, so it makes the perfect option for electronics that need to send and receive electric signals. ABS enclosures are a great choice for indoor projects. Available in a multitude of sizes, ABS enclosures provide sturdy and protective housings for all kinds of electronics. Alternatively, polycarbonate enclosures are the perfect solution for boxes that are used outdoors and need to withstand severe weather conditions.

Benefits of Plastic Enclosures Include:

• Non-conductive
• Lightweight
• Allows passage of radio frequency
• Economical
• Non-reactive in most environments
• Non-Corrosive
• Available in transparent/clear color option

The Bottom Line

Our aluminum and plastic enclosures each offer their own benefits depending on your electronics design needs. Plus, both aluminum and ABS plastic are recyclable materials, so we help you create enclosures that are a sustainable part of the lifecycle for your project.