Did You Know? Aluminum is 100% recyclable, making it the top choice for eco-conscious "Green Home" brands. Unlike plastic, which loses quality when recycled, aluminum can be reused infinitely without losing its premium metallic luster.

DFM Checklist: Designing Aluminum Housings for ElectronicsBefore you export that STEP file for a quote, run through this quick checklist to ensure your phone case or atomizer design is ready for manufacturing.1. Wall Thickness:CNC: We can machine down to 0.5mm walls for ultra-slim devices, but 0.8mm - 1.0mm is safer to prevent vibration and chatter marks.Die Casting: Aim for a uniform 1.5mm - 2.0mm. Avoid sudden changes in thickness to prevent cooling distortion.2. Internal Corner Radii (CNC Specific):Avoid sharp internal 90° corners.Rule: The internal radius should be at least 1/3 of the depth of the pocket. (e.g., A 10mm deep pocket needs a  3.3mm radius). This allows us to use larger, stiffer tools for a better finish and lower cost.3. Threading & Assembly:High Cycle Use: If the user will open/close the device frequently (e.g., battery doors), do not tap directly into the aluminum. Design for steel threaded inserts (Helicoils) to prevent stripped threads.Standard Use: Standard tapped holes are fine. Keep hole depth to 2 \times diameter.4. Surface Finish Allowances:If you require Hard Anodizing or Powder Coating, remember this adds thickness!Anodizing: Adds approx 10-20 microns.Powder Coat: Adds approx 60-100 microns.Pro Tip: Adjust your CAD tolerances for mating parts (like buttons or sliding covers) to account for this growth.5. Undercuts:CNC: Undercuts require special T-slot cutters or multi-axis machining (5-axis), which increases cost. Only use them if absolutely necessary for PCB snap-fits.Die Casting: Avoid undercuts entirely if possible; they require expensive "slides" in the mold.