CUSTOM SHEET METAL MANUFACTURING
You Buy Manufacturing Capability, Not a Fixed Product
Every EV charger protection box on this page was built for a specific project, which means the dimensions, material, protection level, door layout and cable entries are decided by the installation rather than taken from a catalogue. Send a drawing, a charger datasheet or even a dimensioned sketch, and we handle the structure, process planning, fabrication and inspection.
Material
SPCC / SGCC / 304 stainless / aluminium 5052
Sealing
IP54 – IP55, heavier gasket package on request
Tolerance
plus or minus 0.1 mm formed, 0.01 mm laser accuracy
Quality system
ISO 9001:2015, CE and SGS verified
- SPCC cold-rolled steel 1.2-2.0 mm, galvanized SGCC, 304 stainless or aluminium 5052 by drawing
- IP54-IP55 sealing as standard, with a heavier gasket and gland package for exposed sites
- plus or minus 0.1 mm on formed enclosures, with plus or minus 0.01 mm laser positioning accuracy
- Full welding, deburring and outdoor powder coating at 60-80 micron film thickness
- In-house laser cutting, CNC punching, CNC bending and hardware installation
- One partner from drawing review to packed, export-ready enclosures
PRODUCT OVERVIEW
Product Overview
EV charger protection boxes are sheet metal housings that enclose an AC wall-box charger when it is installed outdoors, in shared parking or on a pedestal, so the charging unit keeps working through rain, dust, sunlight and casual interference. The enclosure carries the door, the lock, the ventilation and the cable opening; the charging unit and its electronics remain the customer’s design.
XHX Metal is a custom sheet metal manufacturer in Dongguan, China, operating a 2,000-square-meter factory with about 30 employees and annual capacity above 500,000 pieces. We build the protection box, the pedestal and the internal mounting plate from your drawing or from the charger datasheet, in small batches or repeat production, with the housing delivered ready for the installer to fit the charger.
Figure 1: A pedestal-mounted EV charger protection box with a sealed cable outlet and a lockable front door.
ENGINEERED FOR OUTDOOR CHARGING
Core Product Advantages
Dual Installation Design, One Body
The same EV charger protection box is supplied as a wall-mounted version on a flat back plate or as a floor-standing version on a formed steel pedestal with a bolted base plate for concrete anchors. A pole adapter is quoted where the site uses round or square posts, so one drawing covers garage walls, driveways, shared parking bays and street-side installation. Internal clearances, cable length and service access are checked against the charger datasheet before production.
Heavy-Duty Material and Outdoor Surface Finish
Body panels of the EV charger protection box are formed from powder-coated steel or stainless, deburred at every edge and stiffened so the door keeps its shape in service. The door closes onto an EPDM or PU gasket, the top edge carries a rain lip and the base is formed with a U-shaped channel and a drain hole so water cannot pool against the door; the cable leaves through a rubber gland that compresses around the sheath. Standard production targets IP54 to IP55, and the finish is an outdoor polyester powder coat cured to a 60 to 80 micron film over phosphate pretreatment.
Ventilation, Cable Management and Locking
Charging units derate or shut down when the air inside the box gets too hot, so the louver pattern is designed around the charger’s heat load instead of being added as an afterthought. On an EV charger protection box, louver panels on the sides or the back let air move across the unit while the formed lips keep rain out, with fan provision, filter pads or a larger vent area quoted where the site is sheltered or the charger runs at full output. The enclosure also provides a sealed cable entry, a strain-relief point and, where the installation calls for it, a formed hook or holster that keeps the connector off the ground. A keyed cam lock is standard; combination locks, double locks and tamper-resistant fixings are quoted for public parking.
Full OEM and ODM Customization
Dimensions, hole positions, door direction, louver pattern, lock type and mounting method of the EV charger protection box are all taken from your drawing. Colour is matched to a RAL or Pantone reference with a physical colour sample approved before the first batch, and the door can be prepared for your name plate, label or marking to agreed artwork.
Figure 2: The wall-mounted version installed in a garage, with the cable leaving through the sealed bottom opening.
Figure 3: Door open, showing the internal mounting plate, the sealed cable gland and the door gasket.
PROBLEM AND SOLUTION
Common Problems This Enclosure Solves
Enclosure does not match the charger module
The body is engineered around your charger dimensions, cable entry and connector clearance
Overheating inside a sealed housing
Louver pattern sized to the heat load, with fan and filter provision where needed
Water and dust reaching the electronics
Gasketed door, rain lip, drained base channel and sealed cable gland, IP54-IP55 as standard
Forced entry at public charging sites
Keyed cam lock as standard, optional double or combination lock and tamper-resistant fixings
Cable strain damaging the entry point
Sealed gland with strain relief, plus a formed hook or holster for the connector
A finish that looks generic or fades
Outdoor polyester powder coat, RAL or Pantone colour matching, approved sample before production
Figure 4: Formed louver ventilation vents and the gasket strip along the door frame.
ENGINEERING SUPPORT
Free Production-Ready CAD Design
Send a charger datasheet, a cable-connection sketch or the mechanical envelope of the installation and the engineering team returns a production-ready enclosure proposal. The review covers internal clearance around the charging module, the gasket path, bend allowances, mounting-hole positions, the cut-out for the display or keypad, and the cable entry that has to line up with the charger terminals. A STEP model and a dimensioned 2D drawing of the EV charger protection box are issued for approval before any tooling or production batch starts, and revisions continue until the drawing is signed off.
- Accepted files: STEP, STP, IGES, DWG, DXF or a dimensioned PDF
- No drawing yet: send charger dimensions, cable positions and mounting type
- Manufacturability feedback on sheet thickness, bend radii and weld positions
- Samples in 5 to 10 working days after the drawing is approved
WHAT YOU CAN CUSTOMIZE
What You Can Customize on an EV Charger Protection Box
Dimensions and Layout
Overall width, height and depth of the EV charger protection box set from the charger body plus the service gap, with single or twin compartments and the door position taken from the installation.
Material and Thickness
SPCC cold-rolled steel, galvanized SGCC, 304 stainless or aluminium 5052, from 1.0 mm to 3.0 mm depending on size, environment and vandal resistance.
Protection Grade
IP54 to IP55 as standard, with a heavier gasket, gland and drainage package quoted for coastal, street-side or high-dust sites.
Door and Access
Single, twin or inspection door, left or right hinge, keyed cam lock, combination lock or double locking point, with the gasket path designed into the frame.
Cable Entry
Bottom or side entries, sealed gland positions and sizes matched to the cable diameter, plus a strain-relief point and an optional connector holster.
Thermal System
Louver vents, fan provision, filter pads or a larger vent area engineered to the charger heat load and the site conditions.
Figure 5: The sealed cable entry, the strain-relief point and a formed connector holster.
CAPABILITY AND SPECIFICATIONS
Manufacturing Capability and Specifications
| Material options | SPCC / SGCC galvanized steel / 304 stainless steel / aluminium 5052 |
| Thickness range | 1.0 – 3.0 mm, selected from enclosure size, environment and impact requirement |
| Protection | IP54 – IP55 standard sealing package; heavier package quoted on request |
| Surface treatment | Outdoor polyester powder coating, 60 – 80 micron, RAL or Pantone matched |
| Welding and assembly | TIG, MIG and laser welding, deburring, hardware and gasket installation |
| Thermal design | Ventilation louvers, fan provision and heat-dissipation openings |
| Cable management | Sealed cable entries, strain relief, cable hooks and connector holsters |
| Human interface | Display or keypad windows, card-reader cutouts, inspection door for isolator or meter |
| Mounting | Wall-mounted back plate / floor-standing pedestal / pole adapter |
| Branding | Name plate, label or marking prepared to agreed artwork; colour matched to sample |
| Packaging | Wrapped and corner-protected in export carton or plywood case |
| Tolerance | Plus or minus 0.1 mm typical on formed enclosures; laser positioning plus or minus 0.01 mm |
FROM RFQ TO DELIVERY
How We Work With You: From RFQ to Delivery
01 · Day 1
Send your requirements
Drawing, charger datasheet or a dimensioned sketch, with material, finish, mounting type and quantity, so we can size the EV charger protection box around the charger.
02 · 1-2 days
Engineering review
We check the internal clearance, gasket path, bend allowance, cable gland position and fixing points.
03 · 1-2 days
Quotation
Factory-direct quotation with material, finish, packaging and lead time stated, plus DFM feedback on the drawing.
04 · 5-10 days
Sample and approval
First-article sample with inspection records and photos for your approval before production starts.
05 · 15-30 days
Production
Batch fabrication with in-process inspection at the critical steps, then powder coating and assembly.
06 · On schedule
Inspection and delivery
Pre-shipment inspection, export packing, and FOB, CIF or DDP terms arranged with your forwarder.
Figure 6: Finished enclosures wrapped with corner protectors and packed for export.
QUALITY CONTROL
Quality Control Before Every Shipment
Dimensional verification
Dimensional verification of the EV charger protection box against the approved drawing, including door fit and gasket compression
Lock and door operation
Lock function and door operation checked on every unit
Coating thickness and adhesion
Coating thickness and adhesion checked, with colour verified against the approved sample
Weld quality and appearance
Weld quality and appearance inspection, with burrs and sharp edges removed before packing
- Pre-shipment inspection records and photos supplied with the batch; SGS inspection or a customer visit welcome
PRICING AND TRADE TERMS
Pricing and Trade Terms
| Quotation | Factory-direct quotation within 1-2 business days of the drawing review |
| Payment | T/T 30 percent deposit and 70 percent balance before shipment; terms agreed for repeat programs |
| Shipping | FOB, CIF and DDP supported; export carton or plywood case with corner protection |
| Program scale | Prototype orders from 1 piece, production MOQ 20-50 pieces for a new size or colour |
Figure 7: A twin-door enclosure for two chargers, wall-mounted in a workplace car park.
WHY XHX METAL
Why XHX Metal
Integrated sheet metal production
Laser cutting, CNC punching, pressing and bending, welding, grinding, powder coating and assembly in one process chain, so there is no outsourcing gap to manage.
Outdoor enclosure experience
Years of fabrication work on outdoor electrical housings, EV charger protection boxes and energy-storage enclosures, with sealing, drainage and corrosion details treated as part of the design.
Flexible MOQ and stable batches
Prototype orders from 1 piece for evaluation, then production batches of 50 to 300 units, with a 2,000-square-meter factory and 500,000-piece annual capacity behind them.
One-stop supporting supply
Matching pedestals, mounting plates, fixing kits, sealing accessories, export packing and technical documents supplied with the enclosure.
Quality evidence is public: the factory runs under an ISO 9001:2015 quality management system and holds CE and SGS certification, and third-party inspection or a customer visit to the Dongguan factory can be arranged before shipment.
Figure 8: Wall-mounted and pedestal versions after powder coating, ready for gasket, lock and hardware fitting.
Figure 9: Pedestal enclosures installed along a commercial parking bay.
FAQ
Custom EV Charger Protection Boxes FAQ
What is an EV charger protection box?
It is a sheet metal housing that encloses an AC wall-box charger outdoors or in shared parking. It provides the door, lock, gasket, ventilation and sealed cable entry; the charging unit and its electronics are supplied by the customer.
What is the minimum order quantity?
Prototype orders are accepted from 1 piece so the design can be evaluated before scaling. Production MOQ is typically 20 to 50 pieces for a new size or a new colour, with batches running from 50 to 300 units.
Can you design the enclosure if we only have the charger dimensions?
Yes. Send the charger datasheet, cable positions and the installation conditions and our engineers will return a manufacturable proposal with the internal clearance, cable entry and mounting layout, together with DFM feedback on your own drawing if you already have one.
What drawing formats do you accept?
STEP, STP, IGES, DWG and DXF files, or a dimensioned 2D PDF. A hand sketch with the key dimensions and the charger model is enough to start the review.
What protection level can the enclosure reach?
Standard production targets IP54 to IP55 using a compressed door gasket, a rain lip, a formed drainage channel and a sealed cable gland. A heavier sealing package is quoted for exposed street-side or coastal installations.
How long do samples and production take?
Samples are produced in 5 to 10 working days after drawing approval, and the first production batch ships in 15 to 30 days depending on quantity, coating and assembly scope. Repeat orders are faster because the programme and colour standard already exist.
Can the same box be wall mounted and freestanding?
Yes. The body is identical and only the base changes: a flat back plate for wall fixing, or a formed pedestal with a bolted base plate for concrete anchors. A pole adapter is quoted separately where the site uses posts.
Do you ship internationally and how is the enclosure packed?
Yes, we export regularly. Each unit is wrapped, corner-protected and packed in an export carton or plywood case, and FOB, CIF and DDP shipping terms are supported.
RELATED PRODUCTS
Related Products and Next Steps
EV charger protection boxes are part of the wider range of EV charging enclosures built in the same factory, alongside custom electrical enclosures, industrial control cabinets and battery storage cabinets. The work uses the laser cutting, CNC bending, welding and powder coating capacity described under our capabilities. Browse the product pages, contact the engineering team with your drawings, or send files through the online quoting form. Technical references for outdoor enclosures and the equipment they protect include NEMA enclosure type definitions, UL Solutions certification routes, SAE International charging standards, and the coating guidance published by the Powder Coating Institute, American Galvanizers Association, SSINA and AMPP.
EV Charging Enclosures
Wall-box housings, charging pedestals and DC station enclosures built from customer drawings.
Custom Electrical Enclosures
Outdoor and indoor electrical housings with sealing, locking and cable-management features.
Industrial Control Cabinets
Welded control cabinets and operator panels for automation and power equipment.
Battery Storage Cabinets
Sheet metal cabinets for battery racks, BMS mounting and energy-storage projects.