Aluminum sheet metal gauge for small project enclosures

[matthuszagh]

I'd like to start making my own sheet metal enclosures for small projects (typically not more than about 6in on a side). For people that do this, what aluminum sheet metal gauge do you typically use? I found a small brake (with fingers) that can go to 16 gauge for aluminum, which feels like about the minimum to not feel like the part is too flimsy. I'd really prefer to use 14 gauge or even a bit thicker if possible, but unfortunately I don't see a way to do that. What do you think? Is 16 gauge enough for the final result to feel solid?

[Someone]

1.3 mm ?

Thats getting pretty flimsy if it is the only structure of the end device. But if the PCB is rigidly attached then it can do ok and I have things built with 1.2mm Aluminium sheet like that.

[matthuszagh]

1.3 mm ?

Thats getting pretty flimsy if it is the only structure of the end device. But if the PCB is rigidly attached then it can do ok and I have things built with 1.2mm Aluminium sheet like that.

Yeah 1.3 mm. Ok, that's what I feared. What do you feel is a better thickness for small enclosures? 1.5 mm? 2 mm?

[thm_w]

1.6mm is fine, you can get a solid enclosure if its designed appropriately. Bend over some edge tabs and screw, rivet, spot weld or something: https://www.instructables.com/A-riveted-metal-box-with-lid/

This simple style is never quite as rigid though: https://www.budind.com/series/general-use-boxes/minibox-small-metal-boxes/#group=series-products&external_dimensions_group=0&internal_dimensions=0

For reference (aluminum):
14 gauge = 1.6mm
16 gauge = 1.3mm
18 gauge = 1.0mm

[matthuszagh]

For reference:
14 gauge = 2.0mm
16 gauge = 1.6mm
18 gauge = 1.2mm

What's the right standard for this? I found 16 gauge = 1.3mm (for aluminum) from a quick search online. Sheet metal gauge always confuses me. I suppose I should just ask the brake vendor what mm thickness it works with.

[jpanhalt]

Likely more important than the gauge will be the alloy.  I suspect boxes are 3003 or maybe 6000 series, not "aircraft 2024," but I would check what Bud uses.  I didn't find that alloy shown, but its boxes are 0.040 (1 mm) aluminum.  One reference uses 5052 aluminum for NEMA enclosures. The harder the aluminum, the greater radius of curvature you will need to avoid cracking. 

An easy way to control curvature is to use a waste sheet on the inside of the bend.

[matthuszagh]

Likely more important than the gauge will be the alloy.  I suspect boxes are 3003 or maybe 6000 series, not "aircraft 2024," but I would check what Bud uses.  I didn't find that alloy shown, but its boxes are 0.040 (1 mm) aluminum.  One reference uses 5052 aluminum for NEMA enclosures. The harder the aluminum, the greater radius of curvature you will need to avoid cracking.

I was planning to use 5052 aluminum based on this post: https://www.protocase.com/blog/2017/02/16/electronic-enclosure-design-101/, but I don't know much about the subject and definitely open to using other materials/alloys per recommendation.

[jpanhalt]

It's the bending radius.  Here's a link:

http://www.cumberlandmetals.com/contact-us/aluminum/minimum-bend-radii/

Note:  2024-T3/T4 isn't even listed.  Its allowable been radius is quite large. 

[thm_w]

For reference:
14 gauge = 2.0mm
16 gauge = 1.6mm
18 gauge = 1.2mm

What's the right standard for this? I found 16 gauge = 1.3mm (for aluminum) from a quick search online. Sheet metal gauge always confuses me. I suppose I should just ask the brake vendor what mm thickness it works with.

oops, yeah edited my post.
I assumed all sheet metal gauges were steel, apparently not, better to just use mm's then.

We use 5052-H32.