Die Cast Aluminum Enclosures | IP67 & EMI Shielded
Aluminum and magnesium die cast electronics enclosures with IP65 to IP68 sealing, EMI shielding, precision O-ring grooves, and machined sealing faces.
Production Capabilities
Component examples for die cast aluminum enclosure
Component Range
Multiple die casting examples from this product family showing the scope of geometries, sizes, and features produced.
Feature Detail
Close-up views of critical features including threads, sealing faces, ribs, fins, bores, and mounting points.
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).
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 |
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.
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 <=1.6 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.
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 |
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)
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
Related
Enclosure inquiry: casting@kastdiecast.com | +86 138 1403 4409 | No.6, Rungu Road, Nanjing, China
Related Resources
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CapabilityQuality Control
Review inspection workflow, traceability support, and process control standards before launch.
Process GuideDie Casting Process
See how casting, trimming, machining, finishing, and inspection fit together in production.
Next StepRequest a Quote
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