Precision Sheet Metal Parts for Communications Equipment (Updated for 2025)

Last updated on July 14th, 2025 at 09:28 am

With many metal fabrication shops to choose from, we’re proud to be a top choice for customers in the communications equipment industry.

Approved Sheet Metal frequently fabricates parts for machines that manufacture a wide range of communications products, including GPS systems, satellite technologies, broadcasting equipment, and other wireless communications devices.

One of the companies we’ve worked with is Gradient Technologies, which we supported through product development and quick-turn prototyping. Once we delivered prototypes that met their specifications, we made a small production run that exceeded their expectations.

Keep reading for more about:

• Popular parts we fabricate for communications equipment manufacturers
• Common materials used for communication equipment
• Challenging features associated with these precision sheet metal parts

Popular Parts for the Communications Equipment Industry

From welding, forming, and hardware insertion to assembly and painting, our sheet metal fabrication shop leverages our full range of capabilities to build parts for customers in communications equipment fields.

We regularly manufacture:

• Bus bars
• Covers
• RF/EMI shields
• Enclosures
• Frames
• Rack mounts
• Small brackets

Engineering Design Guidelines for RF/EMI Shielding and Thermal Management

Designing precision sheet metal parts for communications equipment often requires more than just mechanical strength-it also demands careful attention to electromagnetic compatibility and thermal performance. At Approved Sheet Metal, we regularly work with engineers to optimize parts for RF/EMI shielding and passive heat dissipation, ensuring signal integrity and long-term reliability in mission-critical applications.

RF/EMI Shielding Best Practices

Shielding enclosures and components from electromagnetic interference (EMI) is a critical function in modern communications systems. To help ensure effective shielding performance, consider the following design tips:

• Material Selection: Choose conductive materials such as aluminum (with chromate conversion coating), stainless steel, or copper. For maximum attenuation, copper and certain nickel-plated steels offer excellent performance.
• Grounding Tabs and Gaskets: Incorporate grounding tabs or seams that allow for direct contact with chassis ground. We also recommend using conductive gaskets to maintain shield continuity around access panels or covers.
• Minimize Gaps and Seams: EMI can leak through even small openings. Overlapping flanges, tight-fitting seams, and continuous welding (or spot welds spaced closely) can reduce leakage.
• Shielding Effectiveness vs. Ventilation: If you need airflow, consider using honeycomb vents or tightly perforated patterns that allow ventilation while still providing attenuation.

Thermal Management Through Sheet Metal Design

Many communications devices generate heat that must be dissipated passively, especially in compact or fanless systems. Our team can help you integrate thermal management features directly into your sheet metal design:

• Embossed Patterns: We can apply embossments that increase surface area for heat transfer while also stiffening the part.
• Louvers and Vents: Closed-end, straight-back louvers formed with our specialized tooling allow airflow while maintaining structural integrity.
• Material Choice: Aluminum and copper offer superior thermal conductivity. Use these materials when heat dissipation is a key concern.
• Strategic Cutouts and Openings: Proper placement of vent holes or cutouts can guide airflow over key components and improve passive cooling.

✅ Pro Tip: If you’re designing a part that needs both EMI shielding and thermal ventilation, let us know early. We’ll help you balance shielding effectiveness with airflow to avoid compromising performance.

Common Metals Used for Communications Equipment

Metal fabrication companies leverage a wide assortment of materials when manufacturing communications equipment. Here at Approved Sheet Metal, you’ll most frequently find us making communications equipment parts with these metals:

Aluminum

An excellent choice for precision sheet metal parts, aluminum is both lightweight and resistant to corrosion. We can chromate-treat your aluminum parts to make them conductive, and anodizing is an option for increased part durability. Certain aluminum alloys offer enhanced machinability and weldability.

Cold-rolled steel

This cost-efficient material offers high stiffness. Powder coating ensures enhanced durability, but because cold-rolled steel is not corrosion-resistant, it’s best suited for indoor applications.

Copper

Perfect for many electrical applications due to its high thermal and electrical conductivity, copper is soft, flexible, and ductile. Copper alloy options offer increased hardness and formability.

Galvannealed steel

Zinc-coated and annealed for durability, this low-carbon steel performs well in wet environments.

Stainless steel

With the stiffness of cold-rolled steel and excellent strength, stainless steel’s chromium and nickel properties make it highly resistant to corrosion.

Challenging Features Common in Communications Equipment

Unusual and complex features are a hallmark of the precision sheet metal parts we fabricate for the communications equipment industry.

We stock a wide assortment of specialty tools in-house and can procure additional tooling when necessary. Be sure to ask if your part requires a tooling order that may extend your lead time. 

Some of the unique features we frequently fabricate include:

Embossments

By rolling sheet metal between patterned rolls, we can stamp the material with your choice of pattern in a repeatable process that won’t alter your material’s thickness.

Embossments are more than aesthetic embellishments; they can enhance your part’s performance by dispersing liquid, minimizing friction, reducing static, improving stiffness and rigidity, elevating traction, and creating additional surface areas for better heat transfer.

Louvers

Formed with a press brake or press punch, louvers provide air ventilation and can aid in assembly. The louver style we make most often is called a “closed-end, straight-back louver.“

Bridges

Our shop has the highly specialized lance-and-form tools necessary for cutting and forming bridges. These raised features serve as card guides, dividers, shear stops, vents, and wire tie-downs.

Trust Approved Sheet Metal for Precision Sheet Metal Parts

Precision sheet metal fabrication is the manufacturing industry’s preferred solution for cost-efficient, high-quality, quick-turnaround communications equipment parts.

Our team works closely with every customer to resolve design challenges and build optimally usable parts that meet even the most stringent functional requirements, from prototypes to finely finished end-use parts.

Among myriad metal fabrication companies, Approved Sheet Metal is a powerful partner when you need superior-quality critical components for your communications equipment.

Request a quote for your next precision sheet metal project, and we’ll get in touch shortly!

Sheet Metal Design for Manufacturing

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Precision Sheet Metal for Communications Equipment FAQ

What are the typical parts fabricated for communications equipment by Approved Sheet Metal?

Approved Sheet Metal offers a diverse range of parts crucial for communications equipment manufacturing. These include bus bars, covers, RF/EMI shields, enclosures, frames, rack mounts, and small brackets.

Which metals are commonly used by Approved Sheet Metal for communications equipment parts?

We primarily work with various materials suited for distinct purposes in communications equipment. Our commonly used metals include aluminum (with options for enhanced conductivity and durability), cold-rolled steel (ideal for indoor applications), copper (known for its electrical conductivity), galvannealed steel (specifically resistant to wet environments), and stainless steel (combining strength with corrosion resistance).

What challenging features does Approved Sheet Metal frequently fabricate for communications equipment?

Our fabrication expertise extends to intricate features crucial for enhanced performance in communications equipment. These encompass embossments, offering benefits such as improved liquid dispersion, reduced friction, and enhanced heat transfer; louvers, aiding in ventilation and assembly; and bridges that serve diverse functions like card guides, vents, and wire tie-downs.

How does Approved Sheet Metal ensure precision and quality in the fabrication of communications equipment parts?

We pride ourselves on using a combination of specialized in-house tools and, when required, additional tooling to ensure precision. Our team collaborates closely with clients to resolve design challenges and meet stringent functional requirements, from prototyping to the production of finely finished end-use parts.

Can Approved Sheet Metal support quick-turn prototyping and small production runs for communications equipment?

Absolutely. We’ve successfully supported companies like Gradient Technologies through product development and rapid prototyping. Once prototypes meeting specifications were delivered, we executed small production runs that exceeded expectations. Our aim is to provide efficient solutions and superior-quality critical components within quick turnarounds.