Bespoke Metal Distribution Unit in Pyramid-Style Enclosure
01/07/2025
Our customer approached us with a request for a custom-designed electrical distribution unit to suit a compact, low-voltage application. The required specification included a 16A 230V single-phase input with through socket, and twelve 13A flush mount outgoing sockets. Crucially, the customer wanted this housed in a unique triangular, “Toblerone-style” enclosure — a shape that posed both design and manufacturing challenges.
The result was a robust and visually distinctive unit, designed, fabricated, and electrically assembled in-house at our Southampton head office.
Specification Summary
- Incoming:
- 1 x 16A 230V 3-pin IP44 Appliance Inlet
- 1 x 16A 230V 3-pin IP44 Through Socket
- Outgoing:
- 12 x 13A 230V 3-pin Sockets
- Enclosure:
- Bespoke triangular / pyramid-shaped design
- 1.5mm zintec steel
- Black polyester powder-coated finish
Design and Manufacturing Process
The project began with a concept discussion and dimensional brief provided by the client. Our in-house CAD design team then developed a custom triangular enclosure layout — sometimes referred to by the customer as a “pyramid” or “Toblerone-style” box — to maximise stability and footprint while offering clear, accessible socket placement.
Once the design was approved, the enclosure was fabricated using our in-house CNC punching machine, followed by precision folding and welding in our metalwork department. The unit was then powder-coated in a durable black finish, offering excellent resistance to the wear and tear of event and site use.
The final stage involved electrical fit-out in our production facility, where all components were fitted and tested to ensure compliance with relevant safety standards and our own high quality expectations.
Result
The finished distribution unit is a practical, durable, and eye-catching solution — ideal for deployment in events, exhibitions, or temporary outdoor installations where reliable 13A socket provision is required from a single 16A supply.
Thanks to our fully in-house process — from CAD design through to metal fabrication and final assembly — we were able to meet the customer’s specification quickly, accurately, and without compromise.
