Aluminum Enclosures

Aluminum enclosures are critical for protecting high-reliability systems exposed to mechanical, thermal, and electromagnetic stresses. Our enclosures are engineered to address key failure modes observed in field-deployed electronics and instrumentation. Design decisions are guided by structural simulation, thermal modeling, and materials compatibility analysis to ensure long-term operational consistency.

Material Type & Grade

High-strength Aluminum Alloy (e.g., 6061-T6, 5052-H32)

Surface Finish

Type II / III Hard Anodized per MIL-A-8625; Optional Alodine Conversion Coating

IP Rating

IP65 / IP66 / IP67 (based on enclosure variant and sealing configuration)

NEMA Rating

NEMA 4, 4X, 6, 12 (depending on design)

Impact Resistance (IK)

IK08 to IK10 compliant based on application and enclosure wall thickness

Product Description

Our enclosures are manufactured from aluminum alloys with high surface conductivity (e.g., 6061-T6 or 5052-H32). The enclosure body, in conjunction with continuous metal-to-metal contact interfaces and optional conductive elastomer gaskets, provides shielding effectiveness exceeding 60–90 dB attenuation across 10 kHz to 10 GHz spectrum.

EMI/RFI Shielding

Up to 60 dB attenuation (10 kHz–1 GHz) with conductive gasket and EMI-ready design

Thermal Management

Passive conduction; optional integrated heatsinks; thermal interface available

Grounding & Bonding Points

Multiple grounding studs; Alodine-treated surfaces for bonding continuity

Sealing System

Silicone/FKM gaskets; custom profile, compression-rated sealing

Fire Resistance Rating

UL 94 V-0 rated gaskets and insulation components

Environmental Compliance

RoHS, REACH, and WEEE compliant

Load Bearing Capacity

Up to 150 kg static (varies by enclosure geometry and mounting configuration)

Operating Temperature Range

–40°C to +125°C continuous exposure (gasket and finish dependent)

UV Stability

UV-resistant coatings; compliant with ISO 4892-2 accelerated UV aging tests

Salt Spray Resistance

>1000 hours per ASTM B117 (with hard anodizing and sealing)

Seismic Rating

Designed to meet Telcordia GR-63-CORE (Zone 4) requirements on request

Mounting Provisions

Internal bosses, DIN rail support, wall/flange brackets, custom hole patterns

Dimensions

Customizable; typical range from 50×50×30 mm to 600×400×200 mm

Weight Capacity

Configurable up to 75 kg dynamic depending on design and mounting scheme

Lock Type

Quarter-turn, cam lock, padlock provisions; tamper-resistant options available

Technical Advantages

Thermal regulation is another critical factor that aluminum enclosures resolve efficiently. In high-power applications or thermally sensitive components, maintaining a stable temperature gradient is essential to prevent component derating or thermal shutdown. The thermal conductivity of aluminum—typically around 205 W/m·K—enables uniform heat dispersion across the enclosure surface. Designs may incorporate fins or integrated thermal interfaces to optimize passive cooling.

In many industrial and outdoor environments, the risk of ingress from dust, water, and chemicals remains a key concern. Aluminum enclosures are often engineered to meet IP65, IP66, or IP67 ingress protection levels, depending on gasket integrity and interface geometry. Machined surfaces with elastomer or fluorosilicone seals provide long-term resilience under exposure to humidity, fluid splashes, or high-pressure washdowns.

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Industry Applications

Defense Systems

Encases mission-critical electronics such as radar modules, fire control systems, and secure communication interfaces in MIL-STD compliant housings.

Telecommunications

Houses RF filters, baseband units, and optical transceivers in macro/micro cell sites requiring thermal dissipation and EMI isolation.

Marine Electronics

Protects navigation, sonar, and engine control systems from salt spray, vibration, and high-humidity marine conditions.

Test and Measurement Equipment

Provides stable thermal and mechanical environments for precision instrumentation and signal acquisition hardware.

Medical Devices

Encloses diagnostic electronics, imaging subsystems, and patient monitoring units with requirements for shielding and sterilization compatibility.

Data Centers

Supports edge server components, power regulation modules, and EMI-sensitive boards in high-density rack systems.

Galvanic Protection and Precision Machining

Material compatibility is critical in assemblies where galvanic corrosion may arise between dissimilar metals. Aluminum enclosures are surface-treated—commonly via Type II or III anodizing per MIL-A-8625—to form a stable oxide layer that prevents electrochemical reactions. For applications requiring electrical continuity, Alodine conversion coatings may be applied.

In multi-PCB or connector-dense systems, precise mechanical alignment is essential. Aluminum enclosures are CNC-machined to tight tolerances for flatness, parallelism, and hole positioning. This maintains spatial accuracy for standoffs, bosses, and guide rails, reducing connector misalignment, board flexing, and thermal-induced strain.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate ensure dimensional consistency for high-density connector layouts?

Frigate uses precision CNC machining with GD&T controls for positional and parallelism tolerances below ±0.02 mm. This ensures connector cutouts and mounting bosses align with tight-pitch, multi-row headers used in compact embedded systems.

Can Frigate’s aluminum enclosures support hybrid assemblies with copper, brass, or stainless steel parts?

Yes. Frigate applies MIL-A-8625 Type II/III anodizing or MIL-DTL-5541 conversion coatings (Alodine) to mitigate galvanic corrosion. Special attention is given to contact resistance and bimetallic surface separation using insulating washers or sealants.

How does Frigate validate ingress protection for outdoor enclosures?

Frigate performs IP testing according to IEC 60529. Gasket compression force, groove geometry, and surface finish are optimized using finite element simulations and verified through real-time spray, dust chamber, or immersion tests.

What thermal dissipation features does Frigate offer in passive-cooled enclosures?

Frigate integrates CNC-machined heatsink fins, internal heat spreaders, and direct-contact thermal interfaces. Aluminum alloys with high thermal conductivity (e.g., 6061-T6 or 1050A) are selected based on simulation data to manage component heat flux up to 50 W/cm².

Does Frigate provide enclosures suitable for shock and vibration-critical systems like defense or rail?

Yes. Frigate designs enclosures to meet MIL-STD-810 and IEC 61373 standards. Mounting points, wall thickness, and rib patterns are optimized to handle impact forces, resonance frequencies, and fatigue cycles under long-term mechanical loading.