Introduction
Designing sheet metal enclosures that are both cost-effective and high-performing requires a strategic approach to Design for Manufacture (DfM). Applying DfM principles early in the design process can enhance manufacturability, reduce costs, and improve overall quality. Here are five practical tips for designing technology enclosures with efficient enclosure manufacturing in mind.
1. Minimise Complexity to Optimise Manufacturability
Every additional bend, radius variation, or compound feature in a sheet metal enclosure increases tooling complexity, production time, and costs. Prioritise uniform bend radii, consistent angles, and straightforward planar surfaces. Reducing geometric complexity streamlines bending, forming, and laser cutting processes, improves dimensional accuracy, and ensures repeatable, high-quality technology enclosures. Additionally, focus on eliminating features that disproportionately drive cost, such as intricate cutouts or sharp compound bends.
2. Standardise Material Thickness
Using standard sheet metal thicknesses provides significant cost savings and ensures consistency in production. Non-standard gauges often require bespoke tooling and can complicate fabrication. Commonly stocked thicknesses for steel or aluminium include 1 mm, 1.5 mm, 2 mm, and 3 mm, although requirements may vary depending on material and application. Standardising materials also helps reduce waste and scrap during production, streamlining enclosure manufacturing and maintaining predictable mechanical properties across batches of sheet metal enclosures.
3. Optimise Bending and Forming
Bending and forming are critical processes in sheet metal enclosure production. Maintain consistent bend angles and follow the recommended minimum bend radii for the chosen material. This approach improves structural strength, reduces stress concentrations, and minimises the risk of cracking or deformation in technology enclosures. Designing with forming constraints in mind also reduces costly secondary operations and increases production efficiency.
4. Design for Efficient Assembly
Incorporating features such as tabs, slots, and interlocking components simplifies assembly, reduces reliance on fasteners, and enhances product reliability. Reducing part count and standardising components improves repeatability and lowers assembly costs. Thoughtful design at this stage ensures smoother enclosure manufacturing and maintains consistent quality across multiple units of sheet metal enclosures.
5. Plan for Finishing Processes
Surface treatments such as powder coating or anodising affect tolerances, fit, and long-term durability. When designing technology enclosures, account for coating thickness, ensure accessible surfaces for uniform coverage, and avoid recessed areas that are difficult to treat. Early planning prevents costly rework, improves the finished product’s durability, and ensures efficient enclosure manufacturing.
What This Means for Your Enclosure Manufacturing Process
Applying DfM principles to sheet metal enclosures delivers tangible benefits: lower production costs, faster lead times, and higher-quality outputs. By minimising geometric complexity, standardising materials, optimising bending, designing for efficient assembly, and planning for finishing processes, you can create technology enclosures that are manufacturable at scale while meeting both function and budget requirements.
Need guidance on bringing your technology enclosure designs to production? Contact our team to discuss how Unifabs can help you design for efficient, scalable manufacturing.
