Electrical Enclosure Design: 9 Key Considerations

When it comes to electrical enclosure design, there are a few key factors to keep in mind. This guide will outline the most important of these factors and at each stage of the design process. This should give you a good starting point to ensure that your electrical enclosure is up to par.

What is an electrical Enclosure?

First, here is the electrical enclosure definition. In general, an electrical enclosure is any box that contains electrical components. This could be something as small as a junction box or as large in an industrial setting.

Electrical enclosure cabinet
Electrical enclosure cabinet
Source: https://ritherdon.co.uk/what-is-an-electrical-enclosure/

Small Electrical Enclosure

Small electrical enclosures range from housings as small as the key fob or USB memory drive to slightly larger boxes mounted on DIN rails. These are mostly for low-voltage applications. They also usually do not require much in terms of cooling or environmental protection

Large Electrical Enclosure

Large electrical enclosures, on the other hand, can be as small as a wall-mounted cabinet or large floor mounted or free standing enclosures. These usually house medium to high voltage equipment and can be used in both indoor and outdoor applications.

Electrical Enclosure Design

Electrical enclosure design includes all the steps involved in creating housing for electrical components. This includes everything from choosing the right material to fabricating the enclosure itself.

In order to ensure that your electrical enclosure will meet the specific needs of your application, there are a few key considerations to keep in mind. These are discussed comprehensively below.

1. Enclosure Application

The first step in electrical enclosure design is to consider the purpose of the enclosure. This will determine the size, shape, and material of the enclosure as well as what needs to be included inside of it.

Evaluate the environment in which the enclosure will be used. This includes both the external environment and the internal environment. External factors to consider include:

  • Temperature
  • Humidity
  • Dust
  • Exposure to weather (rain, snow, sun, etc.)
  • Salt spray

Internal factors to consider include vibration, shock, and thermal cycling. Evaluating these factors will help you determine what needs to be done in order to protect the electrical components inside the enclosure.

Metal Electrical Enclosure
Metal Electrical Enclosure
Source: https://www.patrykchylinski.com/

2. Enclosure Material

The material you choose for your electrical enclosure will have a big impact on its performance. Enclosures can be made from a variety of materials, including plastic, fiberglass, aluminum, and steel.

  • Aluminum enclosures are a popular choice because they are lightweight and heat-resistant. However, they are not suited for applications where the enclosure will be subject to high levels of corrosive materials.
  • Steel, on the other hand, is very strong and durable enclosure material. Stainless steel enclosures, in particular, offer more advantages than carbon steel enclosures, but are more expensive.
  • Plastic is another popular choice for electrical enclosures. Plastic enclosures are generally less expensive than metal enclosures, but not as strong or durable.
  • Fiberglass is lightweight and low-cost, making it a good choice for enclosures that need to be strong but lightweight. However, fiberglass enclosures are not as heat-resistant as some of the other materials on this list.

Overall, the enclosure material you choose for your project should be based on the specific needs of your application.

3. Enclosure Dimensions

The size and shape of your electrical enclosure is also a major consideration. For example, large electrical enclosures will generally be more expensive than smaller ones. They will also require more space for installation and may be more difficult to transport.

On the other hand, small enclosures may not be able to accommodate all of the electrical components you need. They may also be more vulnerable to damage and easier for unauthorized personnel to access.

When choosing the dimensions of your electrical enclosure cabinet, it is important to strike a balance between size and cost. The enclosure should be large enough to house all of the components you need, but not so large that it becomes excessively expensive or difficult to install.

4. Enclosure Cooling

Another step in electrical enclosure design is to consider the cooling method. This is particularly important for enclosures that will be used in hot environments or that will house heat-generating components. Some common enclosure cooling methods for electrical enclosures include:

  • Airflow (natural or forced)
  • Air conditioners
  • Heat sinks

5. Enclosure Ventilation

The next step is to determine the ventilation requirements of the enclosure. This includes both the amount of ventilation required and the location of the vents. Some common enclosure ventilation requirements include:

  • Providing airflow for cooling
  • Preventing the buildup of dangerous gases
  • Reducing the risk of explosion

6. Enclosure Accessories

Once your electrical enclosure has been fabricated and finished, it will need to be equipped with the appropriate accessories. Enclosure accessories can include everything from ventilation fans to cable glands. Some important accessories include:

  • Enclosure ventilation fans to cool enclosed electrical components
  • Cable glands to seal and protect cables as they pass through the enclosure wall 
  • Enclosure locks for preventing unauthorized access to the enclosure
  • Enclosure hinges to allow the enclosure door to be opened and closed
  • Enclosure latches for keeping the enclosure door closed
  • Enclosure feet that serve to raise the enclosure off the ground and provide stability
  • Enclosure brackets are used to mount the enclosure to a wall or other surface
  • Enclosure gaskets to seal the enclosure door or window
  • Enclosure filters used to remove dust and other contaminants from the air
  • Enclosure door handles to open and close the enclosure door.
  • Enclosure lighting to illuminate the interior of the enclosure.

Enclosure thermal management products are used to regulate the temperature inside the enclosure. They are available in a variety of styles, including air conditioners and heat sinks or heat exchangers.

Enclosure environmental monitors are used to monitor the conditions inside the enclosure. They are available in a variety of styles, including temperature sensors, humidity sensors, and pressure sensors.

7. Enclosure Ratings

During the electrical enclosure design process, one of the first decisions that must be made is what NEMA, IEC, or another type of enclosure ratings will be used.

There are several factors that must be considered when choosing the enclosure rating method, including:

  • Operating environment: Indoor or outdoor? Dusty or clean? Hot or cold? Wet or dry?
  • Protection required: Against mechanical impact? Against ingress of water or other liquids? Against corrosion? Against fire?

Once the decision has been made to use specific protection, the next step is to select the specific rating. Some of the common enclosure ratings and enclosure standards are NEMA, UL, IP, and RoHS.

Steel Pole Mounting Electrical Enclosure
Steel Pole Mounting Electrical Enclosure
Source: https://ph.rs-online.com/web/p/enclosure-accessories/9021879

8. Enclosure Mounting

Electrical enclosure design must also take into account how the enclosure will be mounted. Depending on the application, enclosures can be wall-mounted, floor-mounted, pad-mounted, pole-mounted, or free-standing.

  • A wall-mounted enclosure is attached to a wall or other vertical surface. It may be flush or surface mounted.
  • A flush-mounted enclosure is mounted into the wall so that the face of the enclosure is even with the surface of the wall, while a surface-mounted enclosure is mounted on the surface of the wall.
  • A pad-mounted enclosure is mounted on a concrete pad and mostly installed outdoors.
  • A pole-mounted enclosure is mounted on a pole or other vertical support.  It’s also mostly mounted outdoors.
  • A free-standing enclosure is not mounted to a wall or other surface. It typically sits on the floor and may be fitted with casters or another type of base for mobility.

9. Enclosure Finish

Electrical enclosure design also includes determining the type of finish to use. hat, in turn, is largely dependent on the environment in which the enclosure will be used. Some common finishes include powder coating, plating, anodizing, and painting

  • Painting is relatively inexpensive and can provide a wide range of colors. However, it is not as durable as some other finishes and may require more frequent maintenance.
  • Powder coating is another common method of enclosure finishing. It is more durable than painting and can provide a wide range of colors.
  • Anodizing is a process that is often used for aluminum electrical enclosures. It creates a durable, corrosion-resistant finish.


The electrical enclosure design process is a critical part of any electrical system. It must take into account the specific needs of the application and the environment in which it will be used. Once the enclosure has been designed, fabricated, and installed, it should provide years of trouble-free service.

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