Manufacturing process

Manufacturing techniques for housings that we can handle

We focus on the manufacturing processes of die casting, plastic injection moulding, extruded profiles, sheet metal technology and milling from solid material in housing construction.

As a complete manufacturer of housings, you have one contact partner – from design to development to toolmaking and series production. We ensure that all these process steps fit together, thereby taking responsibility for the quality and function of the housing.

With this concept, we have been successful in the market for years. Our strength is not in simply making the parts, but in giving you a finished, refined product – be it by post-processing, painting, and assembly.

Our manufacturing process

Aluminium die casting

Do you have higher requirements for mechanical, thermal or EMC properties? Then, die-cast aluminium housings are the right solution. In aluminium die casting, molten aluminium is pressed into a die casting mould. Phoenix Mecano operates its own modern die casting plant in India. With this process, complex aluminium housings can be manufactured at low cost.

After washing, the housings are passivated and painted, giving them the necessary protection against corrosion.

Plastic injection moulding

In plastic injection moulding, plastic granules are liquefied and injected into the mould under pressure. The moulded parts can be used and installed directly after the injection moulding process without any post-processing. Plastic injection moulding is used mainly for large series. However, there are tool technologies that are also suitable for small series.

For smaller series or pilot series, aluminium tools, so-called “soft tools”, can be used. In addition to the favourable cost, you have the advantage of a very short manufacturing time of the tools. The first series parts are moulded in just a few working days. This gives you a short “time to market” which helps you when the project is under time pressure.

For large quantities or for very complex parts, classic steel tools are the best choice. In addition to its development expertise, Phoenix Mecano has its own injection moulding operations worldwide, which process most commercially available plastics. Our development department also assists customers in the choice of materials, which is highly dependent on the use of the parts.

Aluminium extruded profile

Aluminium extruded profile – Remain flexible in length

With a punch aluminium is pressed through the die (tool), which determines the shape of the profile. The raw 3 – 6 meter aluminium rods are then anodised or painted and cut to the desired length.
Recessed surfaces for membrane keypads, grooves for accommodating circuit boards or cooling fins can be moulded into the profile right away. Due to the flexibility in length, there is an easy possibility to produce different housing variants and products from one tool. The profiles are then completed with end caps to form a housing. Depending on the required protection class and design, the covers are milled or punched from die-cast, plastic, or sheet metal.

CNC milling from solid aluminium

Design and heat dissipation

Milling housings from solid aluminium material has become increasingly important in recent years. The excellent heat dissipation of aluminium is perfect for HMI panels or panel PCs. Subsequent anodising also gives the housing a high-quality and noble appearance.
Often this process is resorted to for prototypes and small series for field tests before the expensive die-casting tools are produced for series production.

Sheet metal technology

Sheet metal technology – Bending / punching / welding

Sheet metal technology is mainly employed in control cabinet construction and 19 inch technology. Other applications include operating and display panels for machine controls as well as desktop or wall-mounted housings. We focused on the materials aluminium, steel plate and stainless steel. Especially for large housings – from a dimension of approx. 600 mm – we rely exclusively on sheet metal, because tooling costs and parts costs in die casting or injection moulding are rarely economical for these housing sizes. Another advantage over the die casting and injection moulding manufacturing processes is that sheet metal technology does not incur any initial costs such as tooling costs. It is therefore a very favourable process for small to medium quantities. After welding and plastering, the housings are powder coated for surface finish.