Behind the Scenes: Crafting Custom RF Shield Boxes and EMI Shielded Solutions

At Nova Shielding, we specialize in custom shielding solutions designed to solve your unique challenges. In this post, we take you behind the scenes into how we design and manufacture precision-built products tailored to your application.

Step 1: Understanding Your Shielding Requirements

Each project begins with a consultation to fully understand the use case. Are you:

• Testing wireless devices using RF test equipment?

• Building secure enclosures for sensitive electronics?

• In need of a durable Faraday box for lab or field use?

We analyze frequency ranges, signal strength, environmental exposure, space constraints, and performance standards to build a complete picture.

Step 2: Engineering Design

Once we understand the challenge, our team gets to work designing a solution that ensures high shielding performance without compromising usability. We use advanced CAD tools and EMI simulation software to optimize everything from wall thickness to gasket placement. Materials are selected based on your exact needs—aluminum, Mu-metal, copper, or composites—ensuring optimal conductivity and durability.

Step 3: Prototyping and Real-World Testing

Before production, we prototype and perform extensive in-house testing using certified RF test equipment. This ensures that our custom shielding solutions meet or exceed target shielding effectiveness levels (often exceeding 100 dB attenuation).

We test for:

• Shielding effectiveness across specified frequency bands

• Access and usability in live testing scenarios

• Grounding, ventilation, and thermal management performance

This stage allows for refinements and performance tuning—so the final product is ready for anything.

Step 4: Fabrication with Attention to Detail

From concept to completion, every product we build is crafted with precision. Our team uses CNC machining, laser cutting, and other advanced fabrication techniques to maintain tight tolerances and ensure shielding integrity.

Fabrication capabilities include:

• Conductive gasket installation

• Custom connectors and filtered I/O panels

• Seam welding for maximum isolation

• Surface treatments and powder coating for durability

No shortcuts. No compromises. Just high-quality EMI shielded boxes built to perform.

Step 5: Delivery, Support, and Long-Term Value

We don’t just ship products—we deliver peace of mind. Whether you’re a testing lab, a hardware startup, or a global OEM, we offer end-to-end support from design to delivery. Our commitment continues long after installation with options for customization, maintenance, and upgrades.

Why Custom Shielding?

While standard options exist, they rarely meet specialized needs. Our custom shielding solutions provide:

• Enhanced shielding effectiveness

• Better form-fit integration with your systems

• Optimized performance for your exact test or use case

Whether you need a single Faraday box or a fleet of RF shield boxes for a lab, our team is here to help. Here are some of our products.

Ready to get started? Contact Nova Shielding Systems today to learn more about how we can partner.