Custom enclosures for electrical control panels: Design and benefits

When designing an electrical system, the choice of the enclosure cannot be left to chance. A custom cabinet or enclosure for electrical control panels is not just a housing: it is an engineered solution that integrates protection, functionality and regulatory compliance, clearly distinguishing itself from standard market solutions.

For electrical installers, system integrators and designers, relying on custom metal enclosures means being able to respond precisely to project specifications, optimize space, simplify installation and ensure long-term safety. At elmec, we combine mechanical expertise, advanced technologies and in-depth knowledge of the electrical sector to manufacture enclosures that enhance and protect the electronics they contain.

Standard enclosures vs custom enclosures: what’s the difference?

Standard electrical cabinets available on the market are designed to meet general requirements and offer predefined dimensions and configurations. They are quick solutions, but often involve compromises: on-site modifications, wasted internal space, difficulties in component layout or integration with other systems.

A custom enclosure, on the other hand, is developed around a specific project. Every dimension, cut-out, ventilation system and closure solution is designed to perfectly match the electrical components, the installation environment and applicable standards. The result? Cleaner installations, easier maintenance, fewer hidden costs and greater long-term reliability.

For electrical installers, this also represents a competitive advantage: the ability to offer differentiated, technically superior and customized solutions that increase the perceived value of the service provided.

Designing custom enclosures: technical and functional criteria

The design of an enclosure for electrical control panels starts with an analysis of technical and operational requirements. What are the key parameters to consider?

Sizing and internal layout

Each enclosure must house electrical components while ensuring sufficient space for wiring, ventilation and future expansions. A custom design optimizes external dimensions and maximizes usable internal space, avoiding unnecessary oversizing.

IP protection rating

The choice of IP rating depends on the installation environment: dusty industrial settings, outdoor installations exposed to weather conditions, or areas with humidity or liquids require enclosures with appropriate protection levels. At elmec, we manufacture enclosures compliant with different IP classes, thanks to precise manufacturing processes and certified gaskets.

Accessibility and maintainability

A well-designed enclosure facilitates access to internal components. Hinged doors with robust hinges, removable mounting plates, organized cable entry systems and secure yet practical locking mechanisms make installation and maintenance operations faster and more efficient.

Thermal management and ventilation

Electronic components generate heat that must be effectively dissipated to prevent malfunctions or damage. Strategically positioned ventilation grilles, appropriate material thicknesses, selected materials and proper ventilation design contribute to keeping internal temperatures under control.

Regulatory compliance and CE marking

Any enclosure intended for electrical applications must comply with European regulations concerning electrical safety, electromagnetic compatibility and material conformity. At elmec, we manage sheet metal processing through traceable and documented processes, supporting customers in preparing the technical documentation required for the CE certification process of the electrical control panel.

Key manufacturing processes for custom electrical enclosures

Manufacturing a custom enclosure requires specific technical expertise and high-precision technologies. At elmec, we manage all key processes in-house to ensure quality, repeatability and compliance.

Precision fiber laser cutting

Fiber laser cutting allows the production of complex geometries with tight tolerances, even on thin sheets or reflective materials such as stainless steel. This technology ensures speed, flexibility and minimal deformation, making it ideal for doors, internal mounting plates, closing panels and other custom-designed components.

CNC-controlled bending

CNC bending ensures precise and repeatable angles, which are essential for proper enclosure closure and component fitting. Our latest-generation press brakes process sheets of various thicknesses while maintaining tight dimensional tolerances, ensuring consistency from prototype to series production.

Punching and fastener insertion

Automated punching enables the creation of holes, cut-outs and seats for self-clinching fasteners with millimetric precision. These elements simplify final assembly and provide mechanical robustness to internal connections, reducing assembly time and improving overall enclosure strength.

Welding and assembly

When required, we perform certified welding on steel and stainless steel, ensuring strong joints suitable for meeting the protection requirements defined by the project. Final assembly is handled internally, delivering complete enclosures ready for electrical installation.

Materials and finishes for long-lasting enclosures

The choice of materials and surface treatments directly affects enclosure durability, safety and performance.

Stainless steel for critical environments

Stainless steel offers corrosion resistance, ease of cleaning and mechanical robustness. It is the ideal choice for industrial environments, outdoor applications or areas with chemical exposure. Post-processing passivation restores the natural protective layer, ensuring long-term performance.

Carbon steel with advanced coatings

For less demanding applications, carbon steel is a cost-effective alternative. Combined with surface treatments such as galvanizing, powder coating or Zn-Al-Mg coatings (such as Magnelis), it provides adequate corrosion protection and mechanical strength.

Aluminium for lightness and thermal conductivity

Where weight is a critical factor or improved thermal dissipation is required, aluminium is an optimal solution. Anodizing enhances surface resistance and offers high-quality aesthetic finishes.

Benefits for electrical installers and system integrators

Choosing custom enclosures for electrical control panels means investing in solutions that simplify daily work and improve final results.

Commercial differentiation

Offering customized solutions allows installers to stand out from competitors, providing end customers with higher-quality service and technically stronger projects.

Reduced installation time

Custom-designed enclosures minimize on-site modifications, simplify wiring and speed up component installation. Less time means lower costs and greater operational efficiency.

Increased reliability and safety

A well-designed enclosure protects electronics from impacts, dust, humidity and interference, reducing the risk of malfunctions and ensuring compliance with electrical safety standards.

Design flexibility

From rapid prototyping to series production, the ability to adapt every enclosure detail to specific requirements enables complex projects to be managed without technical compromises.

From design to finished product: the elmec method

At elmec, every enclosure is developed through direct collaboration with the customer. We start from your technical drawing, an existing sample or an idea to be developed, and deliver an optimized solution ready for electrical integration.

Our process includes:

• Preliminary technical analysis: evaluation of specifications, installation environment and regulatory requirements
• 3D design and validation: CAD model development and dimensional verification with the customer
• Rapid prototyping: production of the first part for testing and functional validation
• Series production: full production management with constant quality controls and complete batch traceability

We also offer additional supply services such as sampling, electronic integration, customized packaging and lean production management to optimize your processes.

Certifications, traceability and CE compliance

Every enclosure manufactured by elmec is produced using certified materials and documented processes. We support customers in preparing the technical documentation required for CE marking, ensuring compliance with applicable European directives.

Quality control is integrated at every stage: from dimensional inspections using calibrated instruments to visual checks of finishes, up to full traceability of materials, processes and treatments. We are also implementing First Article Inspection (FAI), an in-depth inspection of the first produced part, to ensure full conformity before starting series production.

Choose elmec for your custom enclosures

Whether you need to develop a single prototype or start continuous production, elmec is a technical partner capable of supporting you at every stage of the project. From sheet metal enclosures for electrical control panels to custom rack cabinets, we develop solutions that work, last and integrate seamlessly into your systems.

Ready to design your next custom enclosure?
Contact us for a personalized technical consultation: we will analyze your needs together and propose the most effective solution for your project.