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What started as a standard 19” rack requirement soon turned into a fully customized engineering project.
A data center company reached out to Mech Power for a compact 1U 19″ rack mount enclosure to accommodate their high-density networking equipment. At first, it seemed like a normal order when a customer requested solutions for rackmount enclosures. But after a closer look, we realized they needed far more than a standard enclosure.
What began as a standard request turned into a custom Mech Flexi Rack Mount Enclosure, a product built to incorporate performance, accuracy, and customization of a product.
What They Needed
Customer approached us with a common challenge many others have faced when considering the 19” rackmount enclosures on the market. They required a rack with enhanced ventilation, custom cutouts, and a front layout designed to fit their preferred switch and display arrangement.
To achieve both usability and performance, they selected our Mech Tech 2U Rack as the base structure with a size of 88mm high, 482.6 mm wide, and 271 mm deep.
- They needed a compact 1U 19″ rack enclosure with a size of 44mm high, 482.6 mm wide, and 371 mm depth to house high-density networking equipment.
- Custom cutouts for the switch and display on a 3.0mm front plate with UV Printing for clear labelling and visual consistency across ports and controls.
- A Black Glossy surface finish to elevate the product’s visual appeal and complement the aesthetics of their equipment.
- Their key requirements included enhanced ventilation for improved airflow, a bottom plate for load stability, and rear access for cable management.
- Integrated handles for easier servicing and tight tolerance control to make accurate fitment during assembly.
On top of that, they wanted integrated handles on a smaller model. It wasn’t a massive rebuild, but it meant a stock product wasn’t an option.
How We Built It
We started with fabrication. For the front, we used laser cutting to make the cutouts and ventilation slots. The 3000 W laser provided the precision we needed, especially since the sheet thickness was heavier. The rear was done with CNC punching. Running at high stroke rates, it allowed us to lay out consistent ventilation quickly. The bottom plate, made from a 1.5 mm thick sheet, added stability without unnecessary weight.
Once the panels were shaped, we bent and formed them into place. After that, we moved to finishing. For the surface finish, we used Black Glossy(RAL 9005), a durable coating selected for its professional appearance and compatibility with anodizing. Special care was taken during the anodizing process to maintain a uniform texture and prevent color variation across joined parts. This gave the enclosure both durability and a professional look.
Assembly and Checks
We added the handles and mounted the plate as requested. We also supplied toggle switch connectors for the fan setup. During assembly, our team identified that the vertical switch arrangement caused clearance issues, so we revised it to a horizontal layout, achieving a cleaner and more functional fit. Then came the checks. Every dimension was measured against the drawings. We looked at the cutouts, tested the ventilation slots, and made sure the finish was even. Nothing left the floor without inspection.
The Outcome
The result was a 19" Rack Mount Enclosure that solved the Customer's airflow and access issues. The extras they asked for weren’t cosmetic; they made the system easier to use and maintain. The redesigned layout reduced assembly time by 40%, improved cooling through optimised rear ventilation, and enhanced brand visibility with a UV-printed logo on the front panel. For us, it reinforced a simple point: custom sheet metal fabrication is not about visual tweaks. It’s about solving real problems that standard enclosures simply can’t.