When an Off-the-Shelf Box Won't Fit
A stock project box almost never fits a real build — the PCB is a non-standard size, the connectors land in the wrong place, there's no mounting boss where you need one, and once you start cutting an extruded box it isn't sealed anymore. A machined enclosure solves that: milled from a solid block of aluminium to the exact internal size, with bosses, connector ports and seal grooves cut in as one part — and no mould or tooling cost, so a single prototype is viable.
EKINSUN machines these from your drawing — or, just as often, from a dimensioned sketch, the parts that have to fit inside, or an existing enclosure you need copied.
Custom Enclosure Specifications
| Attribute | Capability |
|---|---|
| Materials | Billet 6061 & 7075 aluminium, brass, steel/stainless, Delrin/PEEK/ABS |
| Construction | One-piece pocketed box + lid, two-part clamshell, or box + panel |
| Sealing | O-ring / gasket groove, lid flatness for IP-rated waterproofing |
| Tolerance | ±0.02 mm on sealing faces, ports and mating features |
| Features | Mounting bosses, connector cut-outs, threaded inserts, vents, fins |
| Finish | Clear/colour anodise, bead blast, laser-engraved legends |
| Size range | ~20 mm pocket boxes up to ~400 mm (larger on request) |
Enclosures We Machine
Electronics / PCB
Sized to a specific board, with standoffs and connector cut-outs
Sensor & instrument housings
Tight ports and faces for sensors, optics and instruments
Waterproof / IP-rated
O-ring groove, sealed glands — outdoor, marine, industrial
Two-part / clamshell
Machined box and lid that locate and seal together
Heat-dissipating
Integrated fins or a cold-plate face for power electronics
Battery / BMS packs
Housings for battery, BMS and power modules
Electrical & Solar: Plates, Panels and Boxes to Your Cut-Out Drawing
A steady share of enclosure work is not a box at all — it is the flat metalwork around electrical gear that catalogues never match: a switchboard panel whose cut-outs must land exactly on your breakers and displays, a gland plate drilled for your specific cable entries, a DIN-rail mounting plate, an inverter or charge-controller bracket, a sealed junction box for one odd position on a solar installation. These are machined the same way as everything else on this page: from your dimensioned sketch or the device itself, from 1 piece.
| Part | What we machine | The honest route when stock fits |
|---|---|---|
| Switchboard & panel plates | Front, middle and rear plates with breaker, display and button cut-outs to your layout | A stock panel that matches your layout is cheaper — they rarely do, which is why these come to us |
| Gland plates | Removable entry plates drilled and tapped for your exact gland sizes and count | Blank stock gland plates exist — the drilling pattern is the custom part |
| DIN-rail mounting plates | Backplates with rail positions, standoffs and earthing points where your build needs them | Stock backplates fit stock cabinets; odd cabinets and retrofits do not |
| Solar connection / junction boxes | Billet boxes with O-ring groove and gland ports, machined for outdoor sealing | Stock IP65 boxes are cheap and good — buy one unless the size, mounting or port layout fails you |
| Inverter & controller brackets | Mounting brackets and adapter plates matched to the unit's holes and your wall or rack | No catalogue lists the bracket between YOUR two hole patterns |
| The electrical internals | Not us: breakers, contactors, wiring and certification are the electrician's supply | We machine the metal; the electrical fit-out stays with your installer |
The solar side of this work — connection boxes, controller housings, complete structural sets for storage systems — has its own hub at custom solar energy system parts; heat-dissipating variants live at heatsink enclosures.
No CAD? Send the Device, a Sketch, or the Old Enclosure
Most enclosure makers assume you'll supply a finished STEP file. Many of our enclosure jobs don't start there — and that's the point:
A sketch + the internals
Outline dimensions plus the PCB / module that has to fit. We lay out the box around it.
The device to house
Send the assembly; we design the housing to its real connector and mount positions.
An old enclosure
Discontinued or cracked — we reverse-engineer it and machine a new one.
Replacing a discontinued enclosure? Send the broken one, even incomplete. We restore the outline, ports and seal grooves to nominal and machine a new billet part — the same way we handle any reverse-engineered part. See also ordering with no CAD.
Sealing & Waterproofing
For IP-rated enclosures the seal is everything. We machine a continuous O-ring or gasket groove, hold the lid and box mating faces flat and parallel (typically ±0.02 mm) so the seal compresses evenly, and machine ports for sealed cable glands or bulkhead connectors. Tell us the IP target, the connectors and the environment (outdoor, marine, washdown) and we design the sealing detail and pick the finish to match.
Finishes
- Anodising — clear or coloured, hard-anodise for wear and corrosion
- Bead blast — even matte texture before anodising
- Laser engraving — legends, port labels, logos, serial numbers
- Inserts — threaded inserts for repeated assembly/disassembly
Typical Applications
- Prototype and low-volume electronics & IoT enclosures
- Sensor, optical and instrument housings
- Outdoor, marine and industrial waterproof boxes
- Battery, BMS and power-module housings
- Replacement enclosures for discontinued equipment
Frequently Asked Questions
Yes. Send a dimensioned sketch, the internal parts or PCB the box has to house, or an existing enclosure to copy. We build the drawing for free, confirm internal layout, port positions and mounting points, then machine it. No CAD file needed to start.
Yes. Send the old enclosure — even cracked or incomplete. We measure the outline, mounting bosses, port cut-outs and seal grooves, restore them to nominal and machine a new one from billet. Same reverse-engineering process we use for any obsolete part.
Yes. We machine an O-ring or gasket groove and hold the sealing faces and lid flatness tight (typically ±0.02 mm) so a captured seal works reliably. Ports can be machined for sealed glands or bulkhead connectors. Tell us the IP target and connectors.
Stock boxes rarely fit a non-standard PCB, connector layout or mounting pattern, and cutting them up isn't sealed. Machining from billet gives the exact internal size, integrated bosses, ports and seal grooves in one part, with no tooling cost — ideal for prototypes and low-to-mid volumes.
Billet 6061 and 7075 aluminium for strength, weight and a clean anodised finish; brass, steel and engineering plastics where needed. Finishes: clear or colour anodise, bead blast, and laser-engraved legends or port labels.
One. Because the enclosure is milled from solid with no mould or tooling, a single prototype is fully viable. Unit price drops on small batches as setup is shared, and we quote all tiers upfront.
Yes — the metalwork side: switchboard front, middle and rear plates with cut-outs machined to your breaker and display layout, gland plates drilled and tapped for your exact cable entries, DIN-rail mounting plates, inverter and controller brackets, and sealed junction boxes machined from billet. From 1 piece, from a dimensioned sketch. The honest boundary: the electrical internals — breakers, wiring, certification — stay with your electrician, and a stock IP65 box is the better buy whenever its size and port layout genuinely fit.
Quote a Custom Enclosure
Sketch, device or old enclosure — all accepted. Reply in 12h.
// Qty & price
1 pc
Prototype
Confirm fit before a run
10–50
Unit price drops
Setup cost shared
100+
Best price
All tiers quoted upfront
- →No distributor — you pay the maker directly
- →CAD saved after first order — reorder anytime at lower unit price