The "outer covering" of projectors and electronic instruments: How to choose between sheet metal bending and aluminum extrusion?

A projector or electronic device is placed on the exhibition stand. Before the user even turns it on, the first impression has already been formed -

Are the seams of the casing uniform? Is the paint surface smooth? Are the corners sharp? Are the ventilation holes exquisite?

These questions may seem like details of the appearance, but in fact, they reflect the comprehensive capabilities of structural design, processing accuracy, and surface treatment. More importantly, the casing also undertakes core functions such as heat dissipation, electromagnetic shielding, and structural strength.

So the question arises: Should the instrument casing be made by bending sheet metal or extruding aluminum?

The answer is not a binary choice; rather, it depends on your product stage and requirements. And our value lies in: Both processes can be carried out, and surface treatments such as spraying, sandblasting, and oxidation can be completed in one step.

Let me quickly help you determine: Which manufacturing process is your casing suitable for?

Both processes are carried out by us. Below, we will introduce them separately. You can choose the one that suits your product's specific situation.

Solution 1: Sheet metal bending for the enclosure - Capable of handling complex structures flexibly

This is the most commonly used process route for the instrument casing, and it is particularly suitable for small and medium batch, multi-variety, and structurally complex projects.

Common materials

Laser cutting: Accuracy ±0.1mm. Can process any irregular holes and heat dissipation hole arrays.

CNC bending: Maximum length 3.2 meters, thickness range 0.5 - 6mm. Bending accuracy ±0.5°

Welding/bracing: Argon arc welding, spot welding, press-fit nuts/screws, facilitating internal board card fixation Post-processing: Drilling, tapping, counterboring, chamfering.

Key points of the structural design for the instrument casing (we will review it for you) Heat dissipation openings:

Arrayed circular holes / rectangular holes / louvers, balancing ventilation and electromagnetic shieldingInterface openings: Precisely positioned USB, HDMI, power, network port and other opening positions correspond to the PCB board

Stiffeners: Large-area thin plates with added stiffeners to prevent deformation upon pressing

Installation structure: Press rivets / screws, slots, rails, facilitating the fixation of internal modules

Option Two: Aluminum extrusion shell - The optimal solution for heat dissipation and lightweightingOption Two: Aluminum extrusion shell - The optimal solution for heat dissipation and lightweighting

If your instrument requires a long rectangular casing, a large number of heat dissipation fins, or a need for profiles as the structural framework, aluminum extrusion is a better choice.If your instrument requires a long rectangular casing, a large number of heat dissipation fins, or a need for profiles as the structural framework, aluminum extrusion is a better choice.

Why are projectors and instruments suitable for aluminum extrusion?

The radiator is integrally formed with the housing: no need for additional assembly of the heat sink, reducing the number of components

Constant cross-section, easy for expansion: the same cross-section can be cut to any length, suitable for serialized products

Light weight, high strength: the aluminum density is only 1/3 of steel, with excellent strength

Good electromagnetic shielding performance: the aluminum material itself has a good shielding effect

Our compressive strength

Common alloys: 6063-T5 (smooth surface, good extrusion property, suitable for the majority of instrument casings)

Molding cycle: First sample available in 2-3 weeks (special sections)

Length range: 50mm - 6000mm, arbitrary cutting

Post-processing: CNC drilling, tapping, slotting, chamfering, fine finishing of end face

Typical compression section characteristics

Internal card slot: Used for fixing the PCB board or the rail

Heat dissipation fins: Increase the heat dissipation area and control the temperature rise

Panel mounting slot: Facilitates embedding the front panel or the rear panel

Wall-mounted/installation slide slot: Facilitates equipment fixation

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Surface treatment: The "last mile" of appearance

Whether you choose sheet metal or extrusion, surface treatment is the key factor determining the final texture of the shell. We offer a full range of surface treatments, completing the process in one step.

Spraying (painting / powder coating) - The most commonly used method, suitable for iron and aluminum components

Pre-treatment (necessary for determining adhesion, cannot be omitted):

Iron parts: Degreasing → Water washing → Silane/phosphating

Aluminum parts: Degreasing → Water washing → Chroming/Non-chrome passivation

Spraying process:

Color and Texture:

Color: Full range of RAL color cards, Pantone, custom based on samples

Texture: Sand texture / Matte / Gloss / Orange texture / Hammer texture / Wrinkled texture

Special Effects: Metallic paint, Matte finish, Semi-gloss

Quality Inspection: Grid test (adhesion level 0) Film thickness tester detection (thickness uniformity) Salt spray test (48-500 hours, as required)

Wire polishing treatment - The exclusive texture of stainless steel/aluminum plates

Straight wire / Messy wire / Snowflake wire

Mesh size: 240# - 600#

Applicable to: instrument panels, front panels, decorative strips

Anodizing - Professional treatment for aluminum parts

Original color / black / other colors

Film thickness: 10-25 μm (ordinary anodizing) / 30-50 μm (hard anodizing)

Applicable to: aluminum extrusion casings, aluminum plate bent casings Electroplating - Decoration and protection for stainless steel / iron parts Chromium plating (bright chrome / matte chrome) Nickel plating

Titanium plating (titanium gold / rose gold / black titanium)

Screen printing / laser marking: Logo, product model, interface identification, scale lines Colors available (black / white / red / blue, etc.)

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Quality Control: Structural Precision + Appearance Consistency

The requirements for the quality of the instrument shell have two aspects: the size must be accurate and the appearance must be consistent.

Size Precision Control

Bent parts: Angle ± 0.5°, Hole Position ± 0.1mm

Extruded parts: Sectional Dimension ± 0.1mm, Straightness ≤ 0.05mm/300mm

Testing Tools: Tri-coordinate Measuring Instrument, Angle Ruler, Marble Platform + Micrometer Appearance Consistency Control

Before Spraying: The jig design ensures that the angle of each product on the spraying line is consistent

During Spraying: Spot-check with Thickness Gauge, adjust spray gun parameters

After Spraying: Full inspection under standard light source (check run-off, orange spots, particles, underpainting, color difference)

Batch Color Difference: Leave samples for comparison to ensure the color is consistent across different batches

Available Reports

Material Certificate

Size Inspection Report

Thickness Report

Grid Test Report

Salt Spray Test Report (issued upon customer request)

These instrument casings have been manufactured by us.

Customization Policy: No minimum order quantity requirement

Minimum Order Quantity: 1 piece of sheet metal, 100 meters of extrusion piece (can be mixed lengths)

Sampling Cycle: Sheet metal 3-7 days, Extrusion mold making 2-3 weeks

Sampling Fee Policy: Can be deducted after confirming the batch order

Design Support: Engineers can assist in optimizing the structure, reducing processing costs or improving appearance

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Cooperation Process (Five Steps)

Send drawings/requirements: Provide drawings (CAD/PDF/STEP) or describe the product application scenario

Evaluation: Reply with process suggestions + quotation + delivery date within 24 hours

Sampling: Arrange sampling after confirmation

Confirmation: Sign the mass production contract after the sample is qualified

Delivery: Include test reports, pack and ship