Custom Electrical Enclosures

Custom electrical enclosure solutions for industrial applications

Whether you’re specifying one prototype or high-volume production, custom electrical enclosures from IP Enclosures deliver durability, compliance, and precision-engineered performance ready to install on day one.

Why Choose IP Enclosures for Custom Projects

At IP Enclosures we specialise in custom electrical enclosure design, engineering and manufacturing to meet unique project requirements across industries including mining, infrastructure, automation, renewable energy, defence, instrumentation, and telecommunications. Our bespoke capabilities go far beyond off-the-shelf products, we partner with customers to deliver fully customised electrical enclosure solutions that perform in real-world operating conditions.

What sets us apart:

Quality & compliance: IEC/EN 62208, IEC/EN 61439 and IEC/EN/AS 60529 (up to IP66), CE, UKCA and UL.
Engineering: 2D and 3D support (DWG, STEP) to visualise, refine and approve before manufacturing.
Built for performance: Fabricated before surface finish to protect structural integrity and long-term sealing.
Prototype to production: One-off prototypes, pilot runs or high-volume custom production.

The IP Enclosures Customisation Advantage

Modifying stock products often results in cutting, drilling and field-fitment that risks protection and adds cost. We take a different approach: engineer your custom requirements into the design and fabrication process, not after. That means:

• Reduced project risk
• Lower installation cost
• No field modification
• Guaranteed IP & IK performance

We deliver ready-to-install custom enclosures, cabinets and control panels that meet both specification and schedule.

Custom Enclosure Design & Engineering Process

We make collaboration simple and efficient:

1. Define Requirements: Tell us your environment, equipment, mounting, and compliance needs.
2. Design & Review: Receive 2D drawings and 3D models for approval or refinement.
3. Prototype / Pilot Build: Validate design performance before full production.
4. Manufacture & Test: Precision fabrication with quality assurance and certification validation.
5. Delivery & Support: Logistics support for delivery worldwide.

Engineered design + precision manufacturing = solutions that fit and protect without compromise.

What We Can Custom Build

Made to Your Technical Specifications

• Non-standard dimensions, complex shapes, multi-door access
• Full customisation including cut-outs, brackets, colours, accessories
• Terminal boxes, wall-mounted enclosures, multi-bay floor standing cabinets, field cabinets, data racks, battery cabinets

Fully Fitted & Ready

• Holes, cut-outs and device mounting plates
• Locking systems, handles and tamper-proof fasteners
• Ventilation, sun shields, climate control
• Viewing windows and operator interfaces
• Internal shelves, brackets and cable management
• Custom colours, branding

Case Study: Global OEM Custom Cabinets

IP Enclosures is proud to be a long-term OEM partner to Sonnen, a global leader in smart energy storage and home battery systems. We design, engineer and manufacture custom cabinets for Sonnen’s energy storage products, supplying these enclosures globally to support their deployment in residential and commercial applications.

While many of the cabinets carrying the Sonnen brand are widely recognised in the market, the enclosures behind those solutions are built by IP Enclosures. This type of arrangement, where we design and manufacture custom products that are branded and marketed by our customers, is a core part of our OEM manufacturing capability. We supply similar custom OEM enclosures to many other global customers. For Sonnen, our solution includes:

• Fully custom enclosure fabrication to specification
• Precision cut-outs and mounting features for energy storage hardware
• Material and finish selection to suit climatic and aesthetic requirements
• Custom branding and process control for global consistency
• Logistics and supply chain support for international distribution

This partnership underscores IP Enclosures’ ability to operate as a trusted OEM supplier, delivering engineered enclosure platforms that perform reliably under brand-specific design, testing and deployment requirements. Whether the cabinet carries your own brand or label, it’s built to the same high standards IP Enclosures is known for, rugged construction, engineered performance and installation-ready precision.

Case Study: Compact Telecommunications Battery Cabinets

IP Enclosures developed fully customised outdoor cabinets designed to house batteries, UPS systems, and associated control equipment for Australia’s national broadband network.

The key engineering focus was effective thermal management to protect battery performance in Australia’s high ambient temperatures. The solution also needed to maintain a compact footprint for deployment in space-restricted field locations.

We designed and manufactured a custom cabinet platform featuring:

• Segregated battery, UPS, and control equipment layout
• Integrated cooling system with fans and filtration
• Ventilated sun shields to reduce solar heat load
• Anti-condensation heaters for moisture control
• Custom colour finish to match deployment requirements
• Optimised internal layout to minimise overall cabinet footprint

The result was a compact, climate-optimised enclosure solution engineered specifically for long-term reliability in harsh Australian outdoor conditions, supporting critical broadband telecommunications infrastructure.

Case Study: Second Life Battery Cabinets

IP Enclosures partnered with CSIRO on a pioneering second-life battery initiative, focused on repurposing hybrid batteries removed from Toyota Prius vehicles. The project aimed to reduce environmental risks associated with battery stockpiling while transforming these assets into a reliable supplementary power source for factory operations.

We measured, designed and manufactured a fully customised battery cabinet system, engineered specifically for this application. The enclosure incorporated:

• A segregated battery storage compartment
• A dedicated control and monitoring compartment
• Custom-fabricated mounting brackets for battery modules
• Structured cable management pathways
• Integrated HMI interface provision
• Custom project branding for CSIRO

The result was a safe, scalable, and professionally engineered enclosure solution supporting circular sustainability objectives while enabling practical industrial energy reuse.

Case Study: Wireless Vehicle Charging System UK

IP Enclosures supported the development of an innovative wireless vehicle charging project deployed in the United Kingdom. The system required a purpose-built enclosure solution capable of protecting sensitive power electronics while ensuring reliable performance in a demanding outdoor environment.

We designed and manufactured a custom-engineered enclosure system, developed specifically for this application. The solution incorporated:

• A precision-fabricated enclosure platform
• Integrated thermal management to control internal heat loads
• An EMC configuration to mitigate electromagnetic interference
• Structured internal layout for power electronics and control equipment
• Outdoor-rated construction suitable for UK site conditions

The result was a robust, technically advanced enclosure solution that supported cutting-edge wireless charging technology while meeting environmental, thermal, and electromagnetic performance requirements.