As the core structural component of industrial control electronics, new energy, and communication computing equipment, the aluminum alloy shell integrates multiple functions of protection, heat dissipation, lightweight, electromagnetic shielding, and appearance decoration. With the explosion of energy storage, vehicle-mounted 800V high-voltage platforms, and AI computing server industries, the domestic aluminum alloy housing market has exceeded 28 billion yuan, with a compound annual growth rate of approximately 12%. The industry is upgrading and iterating from pure metal processing to integrated solutions of housing + heat dissipation + shielding + sealing.
一. Diversified molding technology (based on diversified shells)
Different molding processes correspond to different product life cycles and batch sizes, which are the core basis for shell selection.
1. Aluminum extruded housing
Aluminum rod extrusion, cutting + CNC secondary processing; small batch proofing friendly, fast delivery, and comes with heat dissipation fins. Mostly used in power supply housings, inverters, lighting housings, and controller housings.
News tip: Prioritize extrusion of the shell during the R&D and proofing stage to avoid blindly opening die-casting molds. Iterative product modifications can easily cause mold scrapping and project delays.
2. CNC fully milled housing
The aluminum block is integrally CNC milled, with high dimensional accuracy, strong expressiveness of special-shaped appearance, and high cost. Suitable for precision instruments, medical equipment, and high-end small batch industrial control housings.
3. High pressure die-cast aluminum alloy shell
The die-casting mold is formed by high-pressure casting, which can integrally form reinforcing ribs and embedded studs, and is suitable for mass production of 100,000-level products. It is mostly used in vehicle parts, power tools, and security equipment casings; ADC12 die-cast aluminum has poor ordinary anodizing effect, so powder spraying and micro-arc oxidation are preferred.
4. Sheet metal aluminum alloy shell
The aluminum plate is bent and welded into shape, and the large box has outstanding cost performance. Mostly used in industrial chassis, 1U-4U server cabinets, and power distribution cabinets.
二. Mainstream aluminum alloy material grades
6061, 6063 (6 series: the most versatile in the industry, excellent extrusion performance, good anodizing effect, selected for most profile shells.
5052: Specially designed for sheet metal shells, with strong corrosion resistance and suitable for outdoor equipment.
7075 (7 series): high strength, military industry, precision instrument housing, high cost.
ADC12 die-cast aluminum: mainstream material for die-casting parts, suitable for large-volume castings.
三. Rich and diverse surface treatment technologies
Surface treatment determines the wear resistance, anti-corrosion, appearance, and conductive shielding performance of the shell, and is a key link in product implementation.
1. Anodizing (sandblasting anode): The first choice for profiles and CNC shells. It is wear-resistant and scratch-resistant. It can be made in black, silver gray, champagne and other colors. It can withstand salt spray up to 1500‑2000h and retains the electrical and thermal conductivity of metal. Die-cast aluminum is not suitable for ordinary anodizing.
2. Hard anodizing: The film layer is thick and hard, suitable for vehicle and industrial wear-resistant parts, and there are fewer color options.
3. Micro-arc oxidation MAO: an emerging popular process in the industry. It can be processed by die-casting and extruded aluminum. It is a ceramic-like membrane with ultra-high wear resistance and salt spray resistance. It is mostly used in high-end car-sized energy storage casings, but the cost is relatively high.
4. Powder spraying (powder spraying): The main process of die-casting and sheet metal shells, covering the pore defects in castings, rich colors, and strong weather resistance; the finished product needs to reserve a bare metal area for insulation and grounding shielding.
5. Electrophoresis and fluorocarbon spraying: outdoor high weather-resistant shell; electrophoresis gloss and high fingerprint resistance; fluorocarbon spraying is UV-resistant and suitable for outdoor equipment.
6. Conductive oxidation: used inside the shell to retain conductive grounding capabilities and achieve EMC electromagnetic shielding.
四. 2026‑2027 Industry Development Trends (News Highlights)
1. Integration of structural functions: The shell is no longer just a protective box, but integrates heat dissipation channels, shielding grooves, and sealing grooves. Integrated structural parts have become mainstream.
2. Popularization of digital simulation: CAE heat dissipation simulation and structural strength simulation front-end, reducing physical proofing and shortening the research and development cycle.
3. Green manufacturing upgrade: Chromium-free passivation, water-based spraying and other environmentally friendly processes are promoted, and the proportion of recycled aluminum materials continues to increase.
4. Increased entry barriers: Vehicle energy storage requires IATF16949, and medical housings require higher standards for tolerances and cleanliness.
5. Release of foreign trade opportunities: Overseas orders continue to grow, and exported housings need to meet international environmental protection certifications such as RoHS.
