Electronic enclosures collage Products & Services

Protocase manufactures fully finished custom electronic enclosures and associated parts from a wide variety of materials and components, in 2-3 days with no minimum order. Protocase also provides expert and affordable enclosure design services.

Electronic Enclosures

Hybrid Enclosures (Extruded/Milled)

Fully Finished
Built in 2-3 Days
No minimum order

Protocase Tech Tip Video
Hybrid enclosures use a combination of extruded sides, sheet metal top and bottom, and custom machined front and back plates.

The end result is a customized PCB enclosure that feels both durable and sophisticated.

We offer 6063 aluminum extrusions in two height options:

  • 1U Height: 1.72" | 43.688 mm
  • 2U Height: 3.47" | 88.138 mm

Protocase can build your completely customized hybrid enclosures in 2-3 days, in the quantity you require (there is no minimum order - ever!). As with all of our enclosures, panels and parts, we offer a wide variety of custom finishes in order to achieve a professional, high-quality look, plus custom cutouts, fasteners and other hardware.

Choose from a wide variety of finishes, graphics and permanent marking, in order to suit your project’s functionality and desired aesthetics.

Hybrid Enclosures (Extruded/Milled) Examples:

Additional Information:


Our stocked extrusions are 6063 Aluminum.

Top and bottom panels specifically must be 0.064" (1.63mm) 5052 aluminum in order to fit the aluminum extrusion's slots.

The machined front and rear panels are typically made from 6061 Aluminum, as this type of aluminum is very easy to machine.


The aluminum extrusions (side rails) come in a bare aluminum mill finish. Powdercoat and/or chem filmed can be applied to the extrusion as a secondary finish. We do not recommend applying anodizing to aluminum extrusions.

The panels in an extruded aluminum enclosure can have many of our finishes applied (either for the entire enclosure, or part-by-part):

*Provided by a third-party supplier for additional leadtime

Graphics & Labelling:

The front, rear, top and bottom panels in a hybrid enclosure can have graphics and other marking applied:

Stocked Extrusions:

The front, rear, top and bottom panels in a hybrid enclosure can have graphics and other marking applied:

Key Dimensions 1U Extruded Enclosure 2U Extruded Enclosure
External Height 1.72" | 43.688 mm 3.47" | 88.138 mm
Internal Height 1.443" | 36.6mm 3.194" | 81.1mm
Maximum Length 35.0" | 889.0mm 35.0" | 889.0mm
Maximum Width 23.0" | 584.2mm 23.0" | 584.2mm
Minimum Length 2.0" | 50.8mm 2.0" | 50.8mm
Minimum Width 1.625" | 41.275mm 1.625" | 41.275mm

We are happy to provide custom or non-stock extrusion profiles for additional charges and an extended lead time.

Design Resources:

Key Resources 1U Extruded Enclosure 2U Extruded Enclosure
Extrusion Dimensions Download (.pdf) Download (pdf)
Side Extrusion Download (.zip) Download (.zip)
Extrusion Case Guide Download (.pdf) Download (.pdf)
Extrusion Case Download (.zip) Download (.zip)

Get started by choosing one of the following easy design options