Aluminum sheet metal gauge for small project enclosures - Page 1
Forum section: electronics / projects

author: matthuszagh
author_rank: Frequent Contributor
timestamp: March 11, 2023, 01:29:23 am
content: I'd like to start making my own sheet metal enclosures for small projects (typically not more than about 6in on a side). For people that do this, what aluminum sheet metal gauge do you typically use? I found a small brake (with fingers) that can go to 16 gauge for aluminum, which feels like about the minimum to not feel like the part is too flimsy. I'd really prefer to use 14 gauge or even a bit thicker if possible, but unfortunately I don't see a way to do that. What do you think? Is 16 gauge enough for the final result to feel solid?

author: Someone
author_rank: Super Contributor
timestamp: March 11, 2023, 01:40:00 am
content: 1.3 mm ?Thats getting pretty flimsy if it is the only structure of the end device. But if the PCB is rigidly attached then it can do ok and I have things built with 1.2mm Aluminium sheet like that.

author: matthuszagh
author_rank: Frequent Contributor
timestamp: March 11, 2023, 01:43:15 am
content: Quote from: Someone on March 11, 2023, 01:40:00 amYeah 1.3 mm. Ok, that's what I feared. What do you feel is a better thickness for small enclosures? 1.5 mm? 2 mm?

author: thm_w
author_rank: Super Contributor
timestamp: March 11, 2023, 01:59:09 am
content: 1.6mm is fine, you can get a solid enclosure if its designed appropriately. Bend over some edge tabs and screw, rivet, spot weld or something:https://www.instructables.com/A-riveted-metal-box-with-lid/This simple style is never quite as rigid though:https://www.budind.com/series/general-use-boxes/minibox-small-metal-boxes/#group=series-products&external_dimensions_group=0&internal_dimensions=0For reference (aluminum):14 gauge = 1.6mm16 gauge = 1.3mm18 gauge = 1.0mm

author: matthuszagh
author_rank: Frequent Contributor
timestamp: March 11, 2023, 02:18:23 am
content: Quote from: thm_w on March 11, 2023, 01:59:09 amWhat's the right standard for this? I found 16 gauge = 1.3mm (for aluminum) from a quick search online. Sheet metal gauge always confuses me. I suppose I should just ask the brake vendor what mm thickness it works with.

author: jpanhalt
author_rank: Super Contributor
timestamp: March 11, 2023, 08:37:30 am
content: Likely more important than the gauge will be the alloy. I suspect boxes are 3003 or maybe 6000 series, not "aircraft 2024," but I would check what Bud uses. I didn't find that alloy shown, but its boxes are 0.040 (1 mm) aluminum. One reference uses 5052 aluminum for NEMA enclosures. The harder the aluminum, the greater radius of curvature you will need to avoid cracking.An easy way to control curvature is to use a waste sheet on the inside of the bend.

author: matthuszagh
author_rank: Frequent Contributor
timestamp: March 11, 2023, 04:18:15 pm
content: Quote from: jpanhalt on March 11, 2023, 08:37:30 amI was planning to use 5052 aluminum based on this post:https://www.protocase.com/blog/2017/02/16/electronic-enclosure-design-101/, but I don't know much about the subject and definitely open to using other materials/alloys per recommendation.

author: jpanhalt
author_rank: Super Contributor
timestamp: March 11, 2023, 04:31:44 pm
content: It's the bending radius. Here's a link:http://www.cumberlandmetals.com/contact-us/aluminum/minimum-bend-radii/Note: 2024-T3/T4 isn't even listed. Its allowable been radius is quite large.

author: thm_w
author_rank: Super Contributor
timestamp: March 14, 2023, 01:22:49 am
content: Quote from: matthuszagh on March 11, 2023, 02:18:23 amoops, yeah edited my post.I assumed all sheet metal gauges were steel, apparently not, better to just use mm's then.We use 5052-H32.