Sheet Metal Electronics Enclosure | Aluminium 5052, Flat Patterns, PEM Hardware, Louvres

Two-part sheet metal enclosure for a small IoT gateway, designed for laser cutting and press-brake bending in aluminium 5052-H32. The base is a 1.5 mm U-tray: front and rear walls with inward lips, plus two narrow end tabs bent up from the floor. Where those tabs leave the floor, the bends get proper relief cuts so the material doesn't tear at the bend ends. The cover is a 1.2 mm inverted U with five formed louvres on each end for airflow. Every bend is modelled with its real inside radius (1t), and the flat patterns are developed from the same numbers (K-factor 0.42, 90° bend allowance 3.35 mm on the base and 2.68 mm on the cover). The flats are 184.7 x 205.4 mm for the base and 241.0 x 110 mm for the cover. Assembly uses self-clinching hardware, so there are no loose nuts inside: eight PEM S-M3 nuts in the lips and tabs take the cover screws, and four PEM SO-M3 standoffs carry the PCB. The front wall has cutouts for two RJ45 ports, USB-C, two status LEDs and a 12 mm power button. The rear wall has a DC jack and two D-shaped SMA antenna holes. Keyhole slots in the floor allow wall mounting. A reference PCB with its connectors is placed in the assembly to check every cutout lines up. Nothing collides. Delivered: STEP assembly with hardware and reference electronics, STEP of each sheet metal part, DXF flat patterns (cut outline, bend lines, louvre forms and PEM locations on separate layers), and renders.