EV Charging Station Enclosures & Charger Housings
Sheet metal and aluminum housings for AC wall boxes, DC fast-charger pedestals, load-management cabinets and charging accessories: cut-outs for displays, connectors, RFID readers and cable management, finished for permanent outdoor installation.
Charger Housings That Survive the Forecourt
A charging enclosure has to look finished on a public forecourt while surviving sun, kerbside splash, salt on winter roads and daily cable handling. That combination — cosmetics plus durability — is a forming, coating and hardware problem before it is anything else.
We build the metal housing only. The charging module, power electronics, display, cabling and the electrical certification of the finished charger remain with you. We make sure the sheet metal arrives consistent enough that your assembly line does not have to rework it.
Closer Look at This Enclosure Type
Representative photographs of the construction, interfaces and installation context for this product family.
Specifications at a Glance
| Parameter | Typical Specification |
|---|---|
| Typical unit | AC wall box housing, DC charger pedestal body, load-management cabinet, cable retractor housing |
| Configuration | Wall-mounted box, free-standing pedestal, twin-outlet column, cabinet with service door |
| Materials | SPCC 1.2-2.0 mm, galvanized SECC, SUS304 for hostile sites, aluminum 5052 / 6061 sheet |
| Size envelope | Wall boxes from 250 × 300 × 120 mm; pedestals up to 400 × 400 × 1800 mm |
| Cut-outs | Display window, connector aperture, RFID / card reader, LED indicator, cable entry, ventilation |
| Outdoor detailing | Sloped top, drip edges, sealed display window frame, gasket doors, rain-shielded vents |
| Security | Cam lock, padlockable handle, tamper-resistant fixings, anti-theft cable management |
| Finish | Powder coat in your brand RAL or textured finish, brushed or anodized aluminum options |
| Representative lead time | Prototype 10-14 days; serial production 20-35 days depending on volume |
The parameters above are representative of typical projects in this category. Your drawing defines the final specification, and every quotation states the scope it covers.
Popular Configurations We Manufacture
Every size and option is customised to your drawing. Use a configuration below as a starting point for your enquiry.
AC Wall Box Housing
Compact housing for domestic and commercial AC charging points with front service access.
| Typical size | 250-450 W × 300-600 H × 120-200 D mm |
| Material | SPCC or aluminum 1.2-2.0 mm |
| Features | Display window, LED aperture, sealed gland entry |
DC Fast Charger Pedestal Body
Tall outdoor body for a fast charger with cable management and service access from the front.
| Typical size | 350-500 W × 1500-2000 H × 250-400 D mm |
| Protection by design | IP54 / IP55 |
| Features | Sloped top, drip edge, gasket door, cable hook |
Charging Load-Management Cabinet
Cabinet housing for the distribution, metering and load-management equipment behind a charging hub.
| Typical size | 800-1400 H × 600-800 W × 300-450 D mm |
| Access | Single or double front door |
| Features | DIN rail plate, gland plates, ventilation |
Materials, Finishes & Customisation
Housing material
| Cold-rolled steel SPCC | 1.2-2.0 mm — the most economical option for indoor and sheltered bays |
| Galvanized steel SECC | 1.0-1.5 mm — better cut-edge corrosion behaviour for outdoor units |
| Aluminum 5052 / 6061 | 1.5-3.0 mm — light bodies, good thermal behaviour, brushed or anodized finish |
| Stainless steel SUS304 | 1.0-1.5 mm — coastal and heavy-splash locations |
Cosmetic & protective finish
| Powder coating | Structural or smooth texture coat in your brand RAL, 80-100 µm |
| Aluminum finishes | Clear or black anodizing, brushed grain, bead blast |
| Printing | Silk-screen or pad-printed branding applied to your artwork |
Customisation
| Display integration | Window frames, bonded glass supports, gasket sealing and internal mounting bosses |
| Cable management | Retractor mounts, cable hooks, strain relief brackets, sealed entry grommets |
| Thermal | Louvre banks, heat-sink interface cut-outs, fan apertures, filtered panels |
How This Product Moves Through the Workshop
Charger housings are built around the interface dimensions that matter: connector aperture position, display window frame, board mounting bosses and cable routes. After laser cutting, we form the body, weld and blend visible seams, then coat before fitting hinges, gaskets, locks and the display frame. A fit check confirms connector and display alignment against your supplied hardware.
- Drawing review with DFM feedback before production release
- Fiber laser cutting of the complete flat pattern in one set-up
- CNC press-brake forming, welding and grinding
- Coating applied before gaskets, hardware and glass are fitted
- First-article and sample inspection recorded for each batch
Common Questions About This Product
Only the housing and its mechanical parts. Power modules, control boards, displays, contactors and the electrical certification of the finished charger are supplied and certified by you. We make the metal parts those components mount into.
Yes. Send the mating part drawings or a sample assembly and we will build the cut-outs, window frame and mounting bosses to those interfaces. For repeating orders we keep the tooling and set-up so the position stays consistent between batches.
Typically a polyester or hybrid powder coat at 80-100 µm over a properly pre-treated substrate, in your brand colour. For coastal or heavy road-salt environments we would recommend galvanized steel or stainless for the external body rather than relying on coating alone.
Yes. Powder coating is available to any RAL reference or to your physical colour sample. We will coat and send a coupon for approval before the production run if colour accuracy is critical to your brand.
We handle everything from a single prototype for your engineering validation through to repeat serial batches. For pilot builds we usually produce the first unit for fit and finish approval, then release the manufacturing batch once you have signed it off.
Guides for This Application
EV Charger Enclosure Fabrication: Wall Box to DC Cabinet
Wall box, pedestal and DC charger cabinet bodies
Read guideOutdoor Durability for EV Charging Enclosures
IP and IK ratings, impact and vandal resistance
Read guideEV Charger Enclosure Design: Structural and Safety Requirements
Separation, earthing, controls and impact
Read guideSend Us Your Drawing
Tell us the enclosure you need, the environment it works in and the quantity — we will return engineering feedback and a quotation, typically within 24 hours on working days.