When it comes to protecting electrical and electronic components, choosing the right enclosure material is essential. Two of the most popular options are stainless steel enclosures and polycarbonate enclosures, each offering unique advantages depending on the environment, application, and budget.
Polycarbonate enclosures are known for their durable and versatile features, such as multi-mounting capabilities, ease of machining and high impact resistance, which enhance their functionality and suitability for various applications.
Stainless Steel enclosures also offer many benefits such as wide customization capabilities, heat dissipation and UV protection. In this guide, we’ll compare the key benefits and drawbacks of both materials to help you make the best choice for your specific needs.
Understanding Polycarbonate Enclosures
Polycarbonate enclosures are lightweight, impact-resistant, and designed to withstand harsh environmental conditions. These enclosures are commonly used in industrial and outdoor settings where exposure to UV rays, moisture, and chemicals is a concern. They are widely used in hazardous applications due to their durability and protective qualities.
Benefits of Polycarbonate Electrical Enclosures
- Durability & Impact Resistance – Polycarbonate is highly impact-resistant, making it ideal for environments where accidental drops or heavy vibrations are possible.
- Corrosion & Chemical Resistance – Unlike metal enclosures, polycarbonate enclosures do not rust or corrode, making them perfect for applications in humid or corrosive environments.
- Lightweight & Easy to Install – Polycarbonate is much lighter than stainless steel, reducing transportation costs and making installation easier, especially in elevated or hard-to-reach locations.
- Crystal Clear Doors – Unlike metal enclosures that require costly windows, Integra offers clear doors for all polycarbonate enclosures. These doors are made of the same heavy-duty polycarbonate material and offer complete visibility into the enclosure.
- Cost-Effective – Compared to stainless steel, polycarbonate electrical enclosures offer a budget-friendly alternative without compromising performance in many applications.
Polycarbonate enclosures come with a variety of accessories such as transparent covers, DIN rails, and wall mount flanges, which can customize and improve their performance. Some enclosures offer a NEMA 6P protection rating which makes them suitable for extreme weather and marine environments. In addition, polycarbonate is easy and safe to machine. Making it easy to add holes for conduit, antennas and other assembly components.
Drawbacks of Polycarbonate Electrical Enclosures
- Lower Temperature Resistance – While polycarbonate can handle a wide range of temperatures, extreme heat exposure may cause warping or material degradation over time.
- Standard Sizing – Polycarbonate enclosures are injection molded meaning the size and physical attributes cannot be customized per order. Integra Enclosures offers the largest selection of polycarbonate enclosure sizes on the market, but for customers wanting a unique size, shape or multi-door enclosures, stainless steel provides a much wider range of capabilities.
Understanding Stainless Steel Enclosures
Stainless steel enclosures are known for their strength, security, and resistance to extreme temperatures and physical damage. These enclosures are often used in heavy-duty industrial settings where protection against impact, corrosion, and environmental hazards is a priority.
Benefits of Stainless Steel Electrical Enclosures
- UV & Heat Resistance – Due to its reflective nature, stainless steel is highly resistant to UV rays. The material won’t degrade due to sun exposure and it dissipates heat more effectively to keep electronics cool.
- Corrosion & Weather Resistance – Stainless steel electrical enclosures resist rust and corrosion, making them a top choice for applications exposed to moisture, chemicals, or marine environments.
- High Heat Resistance – Unlike polycarbonate, stainless steel can withstand extreme temperatures without warping or degrading.
- Highly Customizable – Each stainless steel enclosure starts out as a flat sheet of metal, providing a much wider range of possibilities in terms of size and shape.
Stainless Steel enclosures are a popular choice for waste water, food and beverage production, and outdoor substations where high heat, moisture and UV exposure are common. Due to the strength of the material, stainless steel enclosures can be manufactured at much larger sizes compared to polycarbonate and can even include multiple doors and unique shapes. These benefits make stainless steel enclosures adaptable to a wide range of applications.
Drawbacks of Stainless Steel Enclosures
- Heavier & More Difficult to Install – Stainless steel is significantly heavier than polycarbonate, making transportation and installation more labor-intensive.
- Higher Cost – While stainless steel enclosures offer superior protection, they also come at a higher price point compared to polycarbonate alternatives.
- Conductivity & Potential Safety Concerns – Unlike polycarbonate, which is an insulator, stainless steel conducts electricity, requiring additional grounding measures in electrical applications. Integra recommends the use of grounding studs and EMI/RFI shielding in sensitive electrical applications.
Choosing the Right Enclosure for Your Needs
Selecting between polycarbonate electrical enclosures and stainless steel electrical enclosures depends on your environment, security concerns, and budget. There are various polycarbonate enclosure models available, each offering unique features, performance ratings, and customization options.
Polycarbonate electrical enclosures are ideal for applications requiring lightweight, corrosion-resistant, and cost-effective solutions, particularly in outdoor or chemical-exposed environments. On the other hand, stainless steel electrical enclosure boxes provide superior temperature resistance, UV resistance and security, making them a great choice for demanding industrial settings with high temperatures and strict safety requirements.
Find the Right Electrical Enclosure
Both polycarbonate electrical enclosures and stainless steel electrical enclosures offer excellent protection for electrical components, but selecting the right material depends on your specific needs. For assistance finding the right electrical enclosure for your project, contact Integra Enclosures – your partner in high quality stainless steel and polycarbonate enclosures.
