Aluminum Die Casting Electrical Enclosures & Parts
A guide to aluminum die casting electrical enclosures and parts: EMI shielding, heat dissipation, IP sealing, ADC12 material, design and OEM ordering.
Aluminum die casting is widely used for electrical enclosures and parts because a single cast body delivers EMI shielding, heat dissipation, mechanical protection and weather resistance. From junction boxes to motor and control housings, die-cast aluminum enclosures protect electronics in demanding environments. This guide covers the benefits, sealing, materials, design and custom ordering.
Why aluminum die casting for electrical enclosures
- EMI/RFI shielding: a conductive aluminum body shields sensitive electronics.
- Heat dissipation: aluminum conducts heat away from power electronics and drivers.
- Ingress protection: with gaskets and impregnation, enclosures reach IP-rated sealing against dust and water.
- Mechanical strength: a rugged housing for industrial and outdoor use.
- Grounding and safety: a solid metal body supports reliable grounding.
Typical electrical parts we die-cast
- Junction boxes and terminal boxes
- Motor housings and end shields
- Power and control enclosures
- Inverter and driver housings
- EV charging and telecom enclosures
- Connector housings and covers
Material
- ADC12 is the standard alloy: good castability, strength, thermal conductivity and pressure tightness for sealed enclosures.
- A380 on request where a customer standard specifies it.
Sealing and IP protection
Electrical enclosures often need to keep dust and water out:
- Machined, flat sealing faces with gasket or O-ring grooves.
- Vacuum impregnation to seal casting micro-porosity for a higher ingress rating.
- Leak or ingress testing where specified.
Design considerations
- Mounting bosses and DIN-rail or PCB standoffs cast in place.
- Cable-gland and connector cutouts, machined to tolerance.
- Wall thickness uniform (typically 2 to 4 mm) for strength without porosity.
- Cooling fins where the heat load is high.
- Draft angles and generous radii for clean casting.
Surface treatment
- Powder coating for corrosion protection and color.
- Shot blasting for a uniform base.
- Conductive or chromate-style finishes where grounding or shielding continuity is required.
Quality and inspection
Sealing-face flatness, cutout positions and overall dimensions are verified on a CMM under an ISO 9001 quality system.
How to order custom electrical die castings
We produce electrical enclosures and parts on a make-to-drawing / OEM basis:
- Send your drawing, 3D model or sample.
- We review sealing, mounting, thermal and machining (DFM) and quote.
- We build the in-house mold and sample on 180 to 500 ton cold-chamber machines.
- CNC machining, impregnation, powder coating and CMM inspection.
- First-article approval, then series production and export.
FAQ
Do aluminum die-cast enclosures provide EMI shielding
Yes. A conductive aluminum body shields electronics from electromagnetic interference.
Can a die-cast enclosure be IP67 or waterproof
With gaskets, sealed machined faces and impregnation, enclosures can reach high IP ratings; the achievable rating depends on the design.
Which alloy do you use for electrical housings
ADC12 as standard; A380 on request to meet a specified standard.
Can you machine connector and cable-gland openings
Yes, cutouts and threaded holes are CNC-machined to tolerance.
Send your drawing for a custom aluminum die casting electrical enclosure — ADC12, sealed, machined, powder-coated and inspected.