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PR313 – Precision Sheet Metal Enclosure for Industrial Cabinets
A process-driven industrial enclosure with controlled welding and coating
Industrial Component Case Study
Hardware fabrication · Sheet metal · Controlled surface finishing
Project Overview
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Project Code: PR313
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Product: Sheet-Metal Enclosure for Industrial Electrical Cabinets
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Application: Internal module for electrical switchboards
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Manufacturing Scope: Laser cutting · Bending · Welding · Surface finishing · Zinc plating · QC · Packaging
At first glance, PR313 looks like a simple metal enclosure.In reality, it is a precision industrial component where mechanical rigidity, surface quality, coating compliance, and logistics protection all had to work together — without compromise.
This project is a clear example of why “simple metal parts” often fail when they are not engineered as a complete manufacturing system.
This precision sheet metal enclosure was developed as a process-driven industrial project, combining controlled welding, zinc coating compliance, and cosmetic surface protection for electrical cabinet integration.
Customer Requirements
The customer requested a compact enclosure designed to be installed inside industrial electrical cabinets, with the following critical requirements:
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Two-thickness steel design
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Thin folded body for efficiency
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Reinforced front plate to support selectors and knobs without flexing
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Strict zinc coating specification
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Uniform zinc layer
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Minimum coating thickness requirement (≥ 7 μm)
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Any non-compliance = rejection
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Cosmetic front surface
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No scratches
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Clean appearance suitable for visible cabinet interfaces
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Safe packaging
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No surface damage during handling or transport
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Why This Was Not a Trivial Job
Combining the following elements creates real industrial risk:
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Mixed material thicknesses (1.0 mm body + 3.0 mm front plate)
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Welded assembly (risk of distortion and misalignment)
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Visible interface surface
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Controlled zinc plating with minimum thickness requirements
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Logistics without cosmetic damage
This is exactly where many suppliers fail — not in cutting or bending, but in process control.
Engineering & Manufacturing Approach
SHAMANA treated PR313 as a process-driven engineering project, not a commodity part.
Design Structure
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Body:
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1.0 mm steel sheet
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Laser cut → bent to shape
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Front Plate:
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3.0 mm steel
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Laser cut separately
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Provides rigidity and stable mounting for controls
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Both components were engineered to work together during welding and plating.
Fabrication Flow
1. Laser Cutting All functional holes and openings were laser-cut to ensure positional accuracy and repeatability.
2. Bending The enclosure body was bent with controlled tolerances, as bending accuracy defines final assembly geometry.
3. Fixture-Based Welding The front plate was welded to the body using controlled fixtures and weld sequencing to:
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Maintain flatness
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Protect hole alignment
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Minimize thermal distortion
4. Surface Preparation Front surfaces were prepared to meet both visual and plating requirements.
5. Zinc Plating with Thickness Control Zinc coating was treated as a functional specification, not a cosmetic step.
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White zinc plating (ISO 2081)
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Controlled racking strategy
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Thickness verification using coating measurement instruments
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Minimum zinc thickness: ≥ 7 μm
Measured values during QC confirmed compliance.
Quality Control Evidence
Quality checks included:
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Dimensional verification (example: 3.0 mm front plate thickness confirmed)
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Zinc coating thickness measurements
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Visual inspection of front surfaces
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Assembly alignment checks
This ensured every part met both mechanical and surface requirements.
Packaging & Logistics Protection
Even a compliant part is unacceptable if it arrives damaged.
Each enclosure was:
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Individually protected in plastic bags
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Packed to avoid metal-to-metal contact
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Secured for transport inside cartons
Result: scratch-free, production-ready parts upon delivery.
What the Customer Received
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A production-ready, two-thickness steel enclosure
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Stable welded geometry with controlled front flatness
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Verified zinc coating compliance
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Clean cosmetic finish
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Logistics-safe packaging
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A repeatable manufacturing process suitable for series production
Why This Case Matters
PR313 demonstrates a core industrial truth:
Simple parts are rarely simple.
When mixed materials, welding, cosmetic requirements, and strict coating specifications come together, success depends on engineering the entire supply chain — not just the drawing.
This is exactly where SHAMANA adds value.
