Industrial EV Charger Enclosure

Engineered for
Durability, Precision, and Scalable Production.

A fully designed, manufacturable enclosure system—from structural skeleton to concrete base mold—built to protect charging hardware in any environment.

The Core Build

• Structural Skeleton – Welded rectangular pipe frame with reinforced flanges for rock-solid mounting.
• Precision Sheet Metal – Front, back, and circular panels with laser-cut holes and pressed bends for perfect alignment.
• Integrated Concrete Base – Custom plastic mold design for casting a permanent, stable foundation with integrated conduit.
• Designed for Assembly – All components feature M10 bolt patterns for straightforward, tooled assembly.
• Production-Ready Design – Optimised for laser cutting, sheet metal press, welding, and casting processes.

The Development Process

1. Concept & Structural Design
   Defining the load-bearing skeleton and interface with the concrete base.
2. Component Design for Manufacturing
   Designing each sheet metal part (Front, Back, Circular Ring) with precise bend allowances and fastener locations.
3. Mold Engineering
   Creating a two-part, keyed plastic mold for the concrete base, including a pipe conduit for cable routing.
4. Assembly & Validation
   Producing assembly drawings, exploded views, and specifying all fasteners (M10 Hex Bolts) for production.

Key Engineering & Manufacturing Solutions

Challenge	Our Solution	Result
Creating a rigid, weather-resistant structure	Welded stainless steel skeleton with gusseted base flanges.	An industrial-grade frame that withstands torsion and environmental stress.
Ensuring panel alignment and serviceability	Precision laser-cut holes and extended flanges on all sheet metal components.	Perfect fit-up and easy disassembly for maintenance.
Integrating a permanent, grounded base	A custom, re-usable plastic mold for casting a concrete pedestal with conduit.	A stable, low-cost foundation with built-in cable management.
Designing for cost-effective, scalable production	Design optimized for standard processes: laser cutting, press braking, welding.	Streamlined manufacturing with multiple sourcing options (U.S. suppliers identified).

The Outcome

A rugged, install-ready product system.

✅ Weatherproof & Vandal-Resistant – Durable stainless steel and concrete base design ensures long-term outdoor performance.
✅ Streamlined Assembly & Installation – Modular design and detailed instructions reduce on-site labor time and cost.
✅ A Professional Market Presence – Sleek, industrial design builds trust and brand authority in the EV space.