10 Tips: Plate & Panel Design

1)  Choose the Right Material for the Application

Different environments require different materials:

• Aluminum: Lightweight, corrosion-resistant, and easy to machine—ideal for rack panels and structural plates.
• Steel: More durable but heavier, suitable for high-stress environments.
  Acrylic or Plastic: Best for lightweight applications and color-coded labeling.
• Brushed vs. Powder-Coated Finishes: Consider aesthetics and durability—powder coating resists scratches better.

BTX offers multiple material options that match your application.

2)  Standardize Connector Cutouts

Keeping your cutout library standardized ensures compatibility and futureproofing. BTX’s software includes pre-loaded cutouts for:

• Neutrik XLR, Speakon, and EtherCON
• D-Series Connectors
• HDMI, USB, and Keystone Jacks
• BNC and RCA connectors
• Custom hole sizes for specialty components

This minimizes errors and ensures a perfect fit for your connectors every time.

3)  Labeling & Engraving: Think Long-Term

• Engraving vs. Silk Screening: Engraved labels are permanent, while silk-screened labels may wear off over time.
• Color-Coded Panels: Consider anodized color-coding for easy identification in large AV systems.
• Readable Fonts: Use clear, high-contrast fonts to improve legibility.

BTX offers laser engraving and silk screening for precise labeling on metal panels.

4)  Plan for Cable Management

A well-designed panel should improve—not hinder—cable organization.

• Include Strain Reliefs: Prevents excessive pull on connectors.
• Use Grommets or Bushings: Protects cables passing through panel holes.
• Positioning: Ensure that connectors allow for proper bend radius and clearance.
  

Proper cable planning can reduce failure points and extend equipment lifespan.

5)  Ventilation Matters

Equipment generates heat, and poorly ventilated panels can lead to overheating.

• Consider Perforations: Pre-cut vent holes help with airflow.
• Spacing Between Connectors: Avoid packing high-power connections too tightly to reduce heat buildup.
• Rack Panel Design: Leave ventilation slots where necessary, especially for power-intensive setups.

BTX offers custom venting patterns for optimized airflow.

6)  Optimize Rack Space Efficiency

Use 1RU and 2RU Panels: Balance space-saving and accessibility.:

• Multi-Function Panels: Combine power, data, and AV connectivity into one panel to reduce clutter.
• Recessed Mounting: Helps protect connectors from accidental damage.

The BTX design software allows you to visualize your panel in real rack layouts to optimize space usage.

7)  Consider Installation & Accessibility

Think about how the panel will be installed and maintained:

• Front-Access vs. Rear-Access Mounting: Choose based on serviceability needs.
• Captive Hardware: Prevents losing screws in critical applications.
  Modular Panels: Allows for easy swap-outs and upgrades.

BTX’s custom punch and machining options ensure easy installation in any setup.

8)  Maintain Proper Grounding & Shielding

For audio, video, and data panels, electrical grounding is crucial:

• Isolated Ground Jacks: Reduces hum and interference.
• Proper Shielding: Use isolated connectors to prevent ground loops in AV systems.
• Use Grounding Lugs: Available in BTX’s custom panel options.

Proper grounding ensures clean signals and reduced EMI issues.

9)  Prototype Before Full Productio

Even with careful planning, prototyping helps catch issues before mass production:

• Order a Single Unit First: Verify fit, finish, and usability.
• Test Connector Spacing: Ensure easy cable insertion and removal.
• Adjust Design as Needed: Make refinements before committing to a large order.

BTX offers low-quantity prototypes so you can test before a full production run.

10)  Use BTX’s Free Plate & Panel Designer for Precision & Efficiency

BTX’s Free Plate & Panel Designer allows you to:

• Select materials, finishes, and colors
• Drag-and-drop cutouts from a preloaded library
• Add labels, engraving, and silk-screening
• Instantly get pricing and lead times

With no software to install, you can design and order your custom panel in minutes—directly from your browser.

Try BTX’s Free Plate & Panel Designer Today!

Final Thoughts:

Designing plates and panels with precision ensures a clean, professional, and functional installation. Whether you need custom rack panels, wall plates, or specialized enclosures, BTX’s custom metalwork division delivers industry-leading solutions.

For expert assistance, contact our team to discuss your next project.

BTX Custom Metalwork – Designed for Installers, Engineered for Performance.