What the Controller Housing Does
The solar charge controller enclosure protects the PCB from moisture, dust, insects and UV radiation while providing ventilation for heat dissipation, cable entry points, and mounting surfaces for wall or panel installation. It is typically the largest individual housing in a portable or residential solar storage product.
We manufacture custom controller housings from any starting point — a reference controller in its existing housing, photos, a hand sketch, or partial CAD. Common configurations include: wall-mount box enclosures, DIN-rail-mount cases, and integrated front-panel housings with display window.
Material Selection for Solar Controller Housings
ASA
Best choice for outdoor installations. UV-stabilised — maintains colour and impact strength after years of sun exposure. Same processing cost as ABS.
ABS + UV Coating
ABS with clear UV-resistant topcoat. Good for semi-exposed locations; more economical tooling than ASA if the coating is acceptable.
Polycarbonate
Maximum impact resistance and inherent UV resistance. Higher material and tooling cost; used when exceptional impact protection is needed.
Aluminium 6061
Powder-coated aluminium for controller housings requiring heat-sinking through the case wall, or for high-end products requiring a premium feel.
6061 detail →Design Features We Build In
| Feature | Options |
|---|---|
| Ventilation | Louvered vent slots (rain-deflecting), mesh grilles (insect-proof, ≤1 mm), solid walls with external heatsink fins |
| Sealing | O-ring groove (IP54–IP65), foam gasket channel, no sealing (IP20 indoor) |
| Cable entry | Moulded-in gland holes, knockouts, cable clamp bosses |
| Mounting | Wall-mount keyhole slots, DIN rail clip groove, surface-mount flange with M4 holes |
| Display window | Clear PC window insert, display cutout only (bare), recessed bezel frame |
| Surface finish | Mold texture, spray paint (RAL/Pantone), powder coat (aluminium) |
No CAD file needed. Send a reference controller in its housing, photos from all angles, or a hand sketch. We measure, rebuild the CAD, confirm all features — then manufacture. Free with your quote.
Frequently Asked Questions
ASA for outdoor installations — UV-stabilised, maintains colour and impact strength over years of sun exposure. ABS with UV coating for shaded outdoor or semi-exposed locations. Aluminium for heat-sinking requirements.
Yes. We design gasket grooves into the enclosure for O-ring or foam gasket sealing, achieving IP54–IP65 depending on geometry. Specify the required IP rating when you enquire.
Yes. Vent slots are designed as structural ribs and grilles in the mold. We size openings to prevent insect ingress (≤1 mm) and orient them to deflect rain while maintaining airflow.
Yes — send a reference controller in its housing, photos, or a sketch. We measure, rebuild the CAD, confirm all features, then manufacture. CAD reconstruction is free with your quote.
// OTHER SOLAR ENERGY SYSTEM PARTS
Quote — Controller Housing
Sample, photo or sketch. Engineers reply in 24h.