As the renewable energy sector continues to expand at an unprecedented pace, so too does the demand for high-quality components that can withstand outdoor environments, variable climates, and long service lifespans. Whether in solar, wind, energy storage, or emerging hydrogen technologies, metal fabrication plays a critical role in the performance and reliability of these systems.
Approved Sheet Metal is uniquely positioned to meet the needs of renewable energy OEMs and engineers. Our core competencies in sheet metal fabrication include high precision and repeatability, proven experience with complex geometries and assemblies, and the agility to quickly move from prototype fabrication to short production runs. With our deep expertise in design for manufacturability (DFM), we help clients avoid common pitfalls and bring parts to market more efficiently.
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Custom Sheet Metal Fabrication for Renewable Energy Applications
Sheet Metal Enclosures and Housing
Renewable energy systems require durable enclosures to protect sensitive components such as batteries, inverters, and power electronics. At Approved Sheet Metal, we fabricate custom enclosures designed to withstand harsh conditions while maintaining optimal thermal and airflow characteristics. Whether it’s a cabinet for an energy storage system or a housing for a microgrid controller, we ensure form, fit, and function are all met with precision.
Solar Power System Components
We regularly produce custom sheet metal components for solar installations, including mounting brackets, racking hardware, and combiner boxes. These parts demand corrosion-resistant materials and reliable, consistent forming to ensure long-term performance, which is why materials like aluminum and stainless steel are often preferred for solar applications.
Wind Energy Parts
Wind turbines and related infrastructure rely on robust sheet metal parts to house control panels, support mechanical systems, and protect sensitive electronics. Our team has delivered wind energy components that must withstand both vibration and environmental exposure, including brackets, panels, and weather-resistant enclosures.
Structural Supports and Frames
Renewable energy projects like hydrogen systems, EV charging infrastructure, and modular power units require custom frames and support structures. Approved Sheet Metal’s ability to fabricate complex welded and bolted assemblies using stainless steel and other rugged materials makes us a valuable partner for these applications.
Air Management Components
Proper airflow is essential in energy storage and power conversion systems. We fabricate louvers, vents, and filter housings that ensure adequate ventilation and protect internal electronics from dust, moisture, and temperature extremes.
Electrical Power Distribution Parts
Precision matters when it comes to electrical safety and efficiency. Our team regularly produces busbar supports, grounding plates, and mounting brackets that organize and shield critical electrical pathways. These parts often demand tight tolerances and reliable repeatability across production runs, a standard we've consistently met thanks to our decades of experience delivering precision sheet metal solutions for high-performance industries.
Sheet Metal Design Considerations for Renewable Energy Fabricated Parts
Material Choice
Choosing the right material is foundational to performance, durability, and cost. For renewable energy parts, we frequently use aluminum alloys like 5052 and 6061, valued for their strength-to-weight ratio and corrosion resistance. Stainless steel, particularly grades 304 and 316, is another top choice for outdoor and marine environments. We also work with galvanized and galvannealed steel for parts that will be painted or powder-coated, cold rolled steel for indoor enclosures, and copper alloys for electrical grounding and conductivity.
| Material | Key Traits | Typical Use Cases |
| Aluminum 5052/6061 | Lightweight, corrosion-resistant | Solar frames, enclosures, EV stations |
| Stainless 304/316 | Strong, high corrosion-resistant | Structural frames, power cabinets |
| Galvanized Steel | Cost-effective, corrosion-resistant | Mounting hardware, electrical panels |
| Cold Rolled Steel | Inexpensive, good finish, indoor use | Control boxes, painted parts |
| Copper | Conductive, corrosion-resistant | Busbars, electrical grounding |
Sheet Metal Fabrication Finish Options
To extend part life and improve aesthetics, we offer a full suite of finishing options including powder coating, anodizing, passivation, zinc plating, wet paint, and chem-film (chromate conversion).
Each finish has specific advantages depending on the intended environment and application. Powder coating, for instance, can add both color and corrosion resistance to your parts, while passivation will enhance corrosion resistance in stainless steel and is commonly used for applications like structural supports or outdoor cabinets.
Sheet Metal Designing for Manufacturability
Early-stage designs sometimes include features that are difficult or costly to produce, including unachievable tolerances, deep flanges, and small bend radii. Our team flags these challenges and recommends adjustments that maintain functionality while improving manufacturability.
Tolerance Stack-Ups
Tolerance accumulation across an assembly can result in misalignment or interference during fit-up. Our engineers identify key functional dimensions and apply best practices to loosen non-critical tolerances, improving yield and reducing cost.
Simplifying Sheet Metal Designs
Some designs include elements like multiple welds or complex contours that can increase production costs. We help simplify parts by consolidating features or converting multi-piece weldments into single-piece formed parts, reducing both lead times and fabrication complexity.
Sheet Metal Assembly and Fitment Issues
Optimizing your design for assembly access, hardware installation, and fastening is important to an efficient fabrication process. At Approved Sheet Metal, we collaborate with customers to identify the best fastener options, hardware placement, and access points, streamlining processes on the shop floor and in the field.
Partner with a Proven Renewable Energy Fabricator
In an industry where every component must be built to last, Approved Sheet Metal has proven itself as a trusted partner for custom metal fabrication. Our deep experience with precision metal fabrication allows us to support clean energy innovators with quality, speed, and expertise.
From material selection to manufacturability review, from sheet metal prototyping to scalable production, we provide the kind of hands-on partnership that helps renewable energy projects succeed. If you're searching for a reliable, knowledgeable fabrication company with proven experience in renewables, look no further than Approved Sheet Metal.
Ready to get started? Contact us today to talk about your next renewable energy project.
