Fabrication and Assembly of Large Enclosure
for the Electronics Industry

Fabrication and Assembly of Large Enclosure for the Electronics Industry When a customer was seeking a reputable contractor to manufacture and assemble their electronic enclosures they turned to Pyramid Fab & Finish for our expertise. With over 40 years experience as a leading sheet metal fabricator, our expert staff was able to explore the project needs and original designs, offer improved engineering solutions, and deliver a product that matched the customer’s specifications at a reduced per-unit cost.

The project, a cuboid metal enclosure, had overall dimensions of 78” x 40” x 24”. According to the client’s specifications, the enclosure needed to be manufactured to a tight tolerance of ±0.005” and finished with a black powder coating for corrosion protection and aesthetic purposes.

Various sized mounting holes were punched into the precut cold rolled steel sheets using large turret press equipment. Brake presses capable of bending sheets up to 12 feet long were used to create the appropriate bend angles for the various components that made up the enclosure, and each part was then powder coated using an in-line Faraday cage booth.

The sequence of assembly and construction was critical in order to properly comply with the customer’s requirements as the assembly consisted of 43 different part numbers with a total of 101 parts-per-enclosure. The structure was connected using 26 different types of PEM fastener inserts, each adding up to a total of 92 pieces per unit. A further 200 pieces of additional hardware were utilized for the final enclosure assembly. Our highly skilled welders then created structurally and mechanically sound welded seams where required.

During fabrication, each of the 101 parts was laser inspected for dimensional correctness. Also, regular in-process inspection of the bends and testing of the powder coating was performed to ensure consistent quality across all units. The enclosure units were personally delivered to the client’s location in Northern Illinois.

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Electronics Enclosure Project Highlights

Product Name & Description

Large Electronic enclosure

Capabilities Applied/Processes


Hardware Insertion
Powder Coating

Equipment Used to Manufacture Part

Turret, Press Brake, Hardware Insertion Machine, Conveyorized Powder Coat Line, Welder

Overall Part Dimensions

78″ x 40″ x 24″

Tightest Tolerances


Material Used

Cold rolled steel

Material Finish

Black powder coating

In process testing/inspection performed

Dimensional Inspection, Visual Inspection

Industry for Use



4 weeks

Delivery/Turnaround Time

Northern Illinois

Standards Met

Customer supplied print, 2D CAD Drawing, 3D Step files

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Overall, the project was a resounding success, and the client was impressed with our ability to seamlessly integrate numerous complex procedures into our manufacturing process, and the quality of the final product also exceeded the client’s initial expectations.

If you would like to learn more about our services and how our team can assist you with your custom manufacturing needs, feel free to contact us or request a quote today.