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It's good to know there is no standard for that.....I'm surprised! I should send ANSI a letter ;) Thanks everyone for clarifying this issue.

I checked their dimensions too. Like you said, they are not exactly the same. I think I should either go with the cap screw idea or use the expensive t-slot nuts... Thanks for your help!

Oh, the web browser messed up my artistic schematic!

For M6 hex screw, the head diameter is 9.78mm. If the bolt diameter is subtracted from it, only 1.89mm remains. That is maximum over lap of the screw head with the edge of the extrusion: |||||||||||||||||||| |||||||||||||||||||| |||||||||||||||||||| 1.89mm overlap =======...

Thanks! It's actually a great idea. I only worry about the smaller surface of the bolt head compare to those special bolts and nuts. Is there something that I am missing?

I was wondering if there are any standards for the size and depth of T-Slot Aluminum extrusions. I have previously used Bosch Rexroth structural framing extrusions (LINK) and they work really good. Now I am in the process of designing a custom extrusion that requires some T-Slot fasteners...

@HDS: Unfortunately I was not able to find any enclosures with dimensions close to what I want :(

Thanks everyone for the great comments.

Thank you! This is a lot of information I can start with. Regarding the plastic sheets: I just read in envplastics.com that their method can compete with sheet metal when the sheet metal process involves welding, grinding and painting. I think for my case sheet metal will be cheaper than sheet...

@1gibson: Thank you for your reply. It seems like the "sheet metal" approach. I like this approach, does it have a specific name? maybe "line bending"? By limited quantity I mean about 20 pieces.

Thank you very much for your reply! For my application implementing a draft will be possible...I should think of vacuum forming. I like the sheet metal idea used by envplastics.com ... I'm wondering if the final cost will e more than real sheet metal or not. I haven't decided on the type of...

Do you have suggestions on what process is the most cost efficient to fabricate limited number of plastic boxes of 24"x36"x2"? the box can be made with one face removed (let's say the large face:24"x36")? I believe any process involving a mold is automatically eliminated since the quantities...

@Bill: Generally modifying a standard one will be a lot more cost efficient. However, for my case the dimensions do not match any thing available. Is there any "standard" or "most efficient" way to design a sheet metal box? I can modify that design to my purpose.

Thank you for all your responses! These are very good points... This thread can become a great reference for everyone else...please add more if you have any other suggestions :)

I am dealing with a cabinet shaped sheet metal box with some large openings on the front and back of the cabinet. I am wondering if anyone has any suggestions to reduce the final cost of fabricating the cabinet. I have already tried using thinner sheet metal, less expensive material, less...