Die Cast Aluminum Enclosures -IP67, EMI Shielded, Outdoor-Ready

Die cast metal enclosures are specified where plastic enclosures are inadequate: when IP67 or higher sealing must be maintained over 10+ year service lives, when EMI shielding is required by regulatory compliance, when structural stiffness must support heavy mounted components, or when operating temperatures exceed plastic service limits.

KastMfg produces enclosures for outdoor telecommunications, industrial automation, power electronics, and consumer electronics in aluminum (A380, A360) and magnesium (AZ91D).

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Enclosure Types

Type	IP Rating	Alloy	Application
Outdoor telecom enclosure	IP65/IP66	A360	5G small cell, Wi-Fi AP
Industrial control box	IP65	A380	Automation controller
Sealed power electronics	IP67	A380 + VADC	Inverter, charger
EV power electronics	IP67	A380 + VADC	Inverter, OBC, DCDC
Laptop/tablet chassis	Cosmetic	AZ91D	Consumer electronics
Handheld industrial device	IP68	AZ91D or A380	Mobile computing
High-pressure wash	IP69K	A380 + VADC	Food industry

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EMI Shielding Performance

Die cast aluminum: 60-70 dB attenuation at 1 GHz (2- mm wall, continuous perimeter contact). Exceeds FCC Class B commercial requirements. Magnesium AZ91D: 60-100 dB at 1 GHz -superior for stringent EMC requirements.

Shield continuity at joints depends on machined flange face quality. KastMfg machines all cover mating faces to 0.01-0.02 mm flatness for continuous metal-to-metal contact.

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IP Rating -Critical Dimensions

Achieving IP67 requires precision O-ring groove geometry, not just a gasket. KastMfg:

• Machines O-ring grooves to AS568 or customer standard -width, depth, and radius per specification
• Verifies groove dimensions on CMM
• Achieves sealing face Ra >=.6 μm
• Performs first-article IP67 immersion test; production verified by air decay

IP69K (high-pressure wash) available with modified groove design providing higher O-ring compression ratio.

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Alloy Selection for Enclosures

Requirement	Alloy
Outdoor coastal installation	A360 (low copper, best corrosion resistance)
Indoor general purpose	A380
Lightweight + EMI shielding	AZ91D magnesium
IP67 + T6 structural	A380 + VADC
Maximum thermal conductivity	A360 or A413

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Surface Finishing for Enclosures

Powder coat (RAL/Pantone, UV resistant) · Anodize Type II (electrical insulation, corrosion) · E-coat (coastal, full coverage including internal) · Chromate conversion (EMI grounding continuity) · Micro-arc oxidation for magnesium (maximum corrosion resistance)

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Applications

Outdoor 5G and telecom equipment · Industrial automation and control cabinets · EV inverter/OBC/DCDC housings · Outdoor power supply enclosures · Medical equipment housings · Laptop and tablet chassis

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Enclosure inquiry: yaoqingpu1983@gmail.com | +86 138 1403 4409 | No.6, Rungu Road, Nanjing, China