Posted on by Carl Marchese
Polycarbonate vs. Metal Enclosures: Which Material Is Right for Your Application?
Introduction
Choosing the right enclosure material is one of the most important decisions when designing an electrical system. While metal enclosures have long been the industry standard, advances in engineered polycarbonate have made non-metallic enclosures an excellent option for many industrial and outdoor applications.
The best choice depends on your operating environment, performance requirements, and long-term maintenance expectations.
Corrosion Resistance
Moisture, chemicals, salt spray, and industrial pollutants can quickly degrade painted metal enclosures. Polycarbonate will not rust or corrode, making it an excellent choice for wastewater, marine, agriculture, and outdoor applications.
Weight Matters
Polycarbonate enclosures are considerably lighter than comparable metal enclosures.
That means:
- Easier installation
- Lower shipping costs
- Reduced structural loading
- Simpler maintenance
Electrical Safety
Unlike metal, polycarbonate is non-conductive. It naturally insulates electrical equipment and won't become energized if an internal fault occurs.
Wireless-Friendly
Modern control systems increasingly rely on Wi-Fi, Bluetooth, cellular communications, and Industrial IoT devices.
Metal enclosures often require external antennas because they can reduce wireless signal strength. Polycarbonate allows radio signals to pass through, making it an excellent choice for connected equipment.
When Metal Makes Sense
Metal still has an important place in industrial applications.
It may be preferred when:
- EMI shielding is required
- Very high temperatures are expected
- Customer specifications require metal
- Heavy structural support is needed
- Sanitary Washdown
Selecting the right enclosure should always be based on the application—not habit.
The Bottom Line
Neither material is "better" in every situation.
However, for many outdoor, corrosive, and industrial applications, polycarbonate offers significant advantages including corrosion resistance, lower weight, electrical insulation, and reduced maintenance.
The best enclosure is the one that matches the environment and protects your equipment for years to come.
Watch the Video
We've recently produced a short comparison video demonstrating the differences between polycarbonate and metal enclosures, including, weight, and impact resistance. Watch the video to see these materials compared side by side.
Need help selecting the right enclosure? Contact the Fibox team to discuss your application and find the best solution for your environment.