CNC Machined Aluminium Enclosure Frame
Open enclosure frames cut from 6061-T6 solid in one clamping sequence: 6 mm walls held to ±0.10 mm, a Ø30 H8 port bore positioned to ±0.03 mm, four Ø8 mounting holes and a lid seat flat to 0.02 mm. Corners are radiused R6 outside and R3 inside so the frame anodizes without a heavy edge build.
- Wall Thickness 6 mm ±0.1
- Bores at ±0.03 mm
- Seat Flat to 0.02 mm
- Square Within 0.05 mm
*Send the lid thickness and gasket type with the drawing. A seat face cut 0.1 mm low will let the gasket relax and the frame will leak at the port, not at the lid.
Aluminium Enclosure Frame Overview
An enclosure frame carries three loads at once: it locates the lid, it holds the port bore concentric with the cable gland, and it sits flat enough on the panel that the gasket compresses evenly. Machining all four walls from a single block keeps those three references tied to one datum instead of to four separate welds or extrusions.
The billet is squared, the pocket is roughed in three depth passes, the port bore is bored rather than interpolated, and the mounting pattern is drilled after the walls are finished so the drill cannot push a thin wall out of square. Every frame is checked on a CMM for bore position, wall thickness and seat flatness before anodizing.
6061-T6 Aluminium
6061-T6 machines to a stable wall at 6 mm, anodizes evenly and keeps an 80 mm frame under 210 g, which matters when the enclosure is mounted on a moving gantry.
6082-T6 or 5052
6082-T6 is the choice when the frame is welded to a base plate, and 5052 is used for frames that are formed from sheet rather than milled, since it bends without cracking at the anodized corner.
Below a 4 mm wall the frame deflects during the finish pass and the port bore drifts oval; if the design needs a thinner wall, the frame is stress-relieved before the final cut.
Enclosure Frame Specifications
Milling data for open frames, with the wall, bore and seat values that decide whether the lid seals and the gland lines up.
| Specification | Machining Data | Specification | Machining Data |
|---|---|---|---|
| Product | Open Enclosure Frame | Process | 3-Axis CNC Milling, Boring, Tapping |
| Material | 6061-T6 Aluminium | Envelope | 80 × 80 × 60 mm |
| Wall | 6 mm ±0.10 mm | Corner Radii | R6 Outside, R3 Inside |
| Port Bore | Ø30 H8, Position ±0.03 mm | Mounting Holes | 4 × Ø8 Through, ±0.05 mm |
| Seat Face | Flatness 0.02 mm, Ra 1.6 | Squareness | 0.05 mm Over 80 mm |
| Threads | M6 × 1, 6H, Depth 12 mm | Internal Pocket | Depth 54 mm ±0.05 mm |
| Edge Break | 0.3 mm × 45° All Machined Edges | Weight | Approx. 205 g |
| Inspection | CMM First Article, Bore Gauge | Batch Size | 10 to 2,000 Pieces |
| Finish | Clear or Black Anodizing | Drawing Format | STEP, DXF, PDF |
Why These Frames Stay Square
One billet, one datum, and a boring pass instead of an interpolated circle.
Walls and Bores From One Set-up
The block is held once while the pocket, the port bore and the mounting pattern are cut, so the bore axis stays perpendicular to the seat face within 0.03 mm and the lid seats without shimming.
Bored Port, Not Interpolated
The Ø30 H8 port is finished with a boring head in two passes rather than a helical interpolation, which holds roundness to 0.01 mm and gives the gland O-ring a true sealing surface.
Seat Face Cut Last
The lid seat is faced after the walls are relieved, removing the 0.05 mm bow that a deep pocket leaves behind, and it is checked on a surface plate before the frame leaves the machine.
Corners Radiused for Coating
R6 outside and R3 inside radii let the anodizing current reach the corners, so the coating builds evenly instead of burning thin on a sharp edge and chalking in the pocket.
Need a frame that seals on the first build?
Surface Finishes for Enclosure Frames
The outside is seen, the inside is shielded, and the seat is masked; each face follows its own rule.
| Finish | Main Purpose | Finish | Main Purpose |
|---|---|---|---|
| Clear Anodizing | General protection, machined faces visible | Black Anodizing | Optical and camera housings |
| Hard Anodizing | Wear face under a sliding lid | Bead Blasting | Even matte before anodizing |
| Chromate Conversion | Conductive frame for earthing | Laser Marking | Part number and port labels |
| Masked Machining | Bare metal on earth pads and gasket seats | Passivation | Only for stainless variants |
| Powder Coating | Outdoor units, thicker build than anodizing | Silk Screen | Front panel legends |
| Ultrasonic Clean | Chip and coolant removal before packing | Sealed Bag | Frames arrive ready to assemble |
*Anodizing adds 10 to 15 µm per face. If the seat and the earth pads are not masked, the lid sits high and the frame loses conductivity to the panel.
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How We Machine an Enclosure Frame
The frame is milled from one billet so the four mounting bores and the port bore share a single datum, and the lid never fights the walls.
01. Drawing and Gasket Review
Check the lid thickness, the gasket groove and the gland thread, then set the seat depth so the gasket compresses by 25 percent at the specified torque.
02. Square the Billet
Face all six sides on a vice with soft jaws, leaving 0.4 mm on the seat face and marking the datum corner that every later operation references.
03. Rough and Finish the Pocket
Rough with a 12 mm end mill at 0.6 mm step-down, then finish the walls at 0.25 mm step-over to control chatter on the 6 mm section.
04. Bore the Port and Drill the Pattern
Bore the Ø30 port in two passes, then drill and tap the M6 pattern in the same clamping so the gland stays concentric with the bore.
05. Deburr, Mask and Anodize
Break every edge by hand, mask the seat face and earth pads, anodize, then re-check the seat flatness after coating.
Send the STEP file and the gland thread, and we will quote a frame with the port bored to your O-ring and the seat depth set from your gasket.
Enclosure Frame FAQs
Yes. The pocket is rough-cycled before finishing and the walls are finished with a light radial cut, which keeps the wall within ±0.10 mm from top to bottom instead of tapering at the floor.
It is bored to whatever the gland drawing calls for between Ø12 and Ø45. The H8 tolerance and the 0.03 mm position are held on the CMM, and the bore is deburred without a chamfer that would cut the O-ring.
Yes. The inside and the seat are masked with tape and plugs, so the shielding face stays conductive and the gasket still sees bare, flat aluminium.
The coating adds about 0.01 mm per face and follows the profile, so the seat stays within 0.03 mm. If the drawing calls for 0.02 mm after coating, the seat is lapped after anodizing.
Yes, and it is the better way to buy it. The lid is cut from the same billet run and match-marked, so the screw pattern and the seat land in the same position on both halves.
Ten pieces for a new drawing, with the first article inspected and photographed before the rest of the batch runs.
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