Die Cast Aluminum LED Cabinet: The Rental & Fine Pitch Standard
500×500 · 500×1000 · 640×480 · 960×960 · 600×337.5 · 480×320 mm — Verified Weights & Pitch Charts
The die cast aluminum LED cabinet is the chassis behind most rental stages and fine-pitch walls: light enough for one-person handling, precise enough for invisible seams. This guide covers every size we build, with verified weights, pitch-to-resolution charts and crew planning — supplied by Excelled, a trusted LED display manufacturer for global B2B system integrators.
Die-Cast Aluminum LED Cabinet at a Glance
What it is: an aluminum alloy chassis formed by injecting molten aluminum into a steel mold, producing thin, rigid, corrosion-resistant cabinet frames — the standard construction for rental and fine-pitch LED walls.
Sizes we build: 500x500mm and 500x1000mm for rental, 640x480mm, 600×337.5mm and 480x320mm for fine pitch, plus 960x960mm for outdoor high-precision fixed installs.
Verified weights: a 500x500mm rental cabinet weighs 7.2 kg indoor / 7.5 kg outdoor (confirmed); a 960x960mm outdoor cabinet weighs 28 kg at 77 mm depth (confirmed); a 480x320mm indoor panel weighs about 3 kg (confirmed).
Quantity rule: four 500x500mm cabinets build 1 m²; a 960x960mm cabinet covers 0.92 m².
Next step: send your target screen size and venue — our engineers return the cabinet grid, resolution and material recommendation.
What Is a Die-Cast Aluminum LED Cabinet?
Die casting forces molten aluminum alloy into a precision steel mold under high pressure. For LED cabinets this produces one-piece, thin-walled frames with cast-in ribs, corner bosses and lock seats — geometry that sheet-metal fabrication cannot repeat identically across thousands of units.
Three properties explain why this construction dominates rental and fine pitch. Rigidity at low weight: cast ribs stiffen the frame so panels stay flat without thick walls. Corrosion resistance: aluminum forms its own protective oxide layer, so a cabinet survives outdoor seasons and humid stage environments without relying on paint alone. Repeatability: identical castings stack into walls with tight, even seams — the difference between a screen that looks like one surface and one that looks like tiles.
A cabinet is only one layer of the display, of course. How modules snap into the cabinet, and how cabinets map to a control system, is explained step by step in our modular LED display system guide.
Available Sizes: From 480x320mm to 960x960mm
The table below lists every die-cast aluminum LED cabinet size in the Excel LED range. Cabinets per square meter is pure arithmetic (cabinet area into 1 m²), which makes it easy to estimate count before you know the final screen design.
| Cabinet Size | Per m² | Typical Application | Weight (confirmed) |
|---|---|---|---|
| 500 x 500 mm | 4.00 | Rental, staging, events | 7.2 kg indoor / 7.5 kg outdoor, 88 mm deep |
| 500 x 1000 mm | 2.00 | Rental, wide-format stage | Per configuration |
| 640 x 480 mm | 3.26 | Fine pitch indoor fixed | Per configuration |
| 600 x 337.5 mm | 4.94 | 16:9 control room and broadcast walls | Per configuration |
| 480 x 320 mm | 6.51 | Compact indoor fine pitch | About 3 kg per panel, 70 mm deep |
| 960 x 960 mm | 1.08 | Outdoor high-precision fixed | 28 kg, 77 mm deep |
(confirmed) figures come from our official specification sheets. Rows marked “per configuration” vary with module layout and pixel pitch, so request the exact figure for your build. For the same sizes across all four cabinet materials, see the LED display cabinet collection.
500x500mm Die Cast Cabinet in Detail: The Universal Rental Size
Four 500x500mm cabinets assemble into exactly one square meter, and because most rental manufacturers follow the same 500mm grid, panels mix across fleets. Our die-cast rental cabinet measures 500 x 500 x 88 mm and weighs 7.2 kg (indoor) or 7.5 kg (outdoor) (confirmed) — light enough for one technician to carry and lock into place overhead.
Inside, the cabinet carries 250 x 250 mm modules and a dual back-up design for both power and signal, so a single connector failure does not black out a stage. The curve lock system lets cabinets angle into concave or convex stage shapes, and modules are front-servable in both indoor and outdoor configurations — a crew swaps a dead module without unstacking the wall.
| Pixel Pitch | Version | Pixels per Cabinet | Brightness / Protection |
|---|---|---|---|
| P2.604 | Indoor | 192 x 192 | 1000 nits · IP40 front / IP20 rear |
| P2.976 | Indoor | 168 x 168 | 1000 nits · IP40 front / IP20 rear |
| P3.91 | Indoor | 128 x 128 | 1000 nits · IP40 front / IP20 rear |
| P3.91 | Outdoor | 128 x 128 | 4500 nits · IP65 front / IP43 rear |
| P4.81 | Outdoor | 104 x 104 | 4500 nits · IP65 front / IP43 rear |
All values (confirmed) per our official MAGIC PRO specification sheet: maximum power 720 W and average 240 W per cabinet. Rigging supports stacking up to 10 m or hanging up to 10 m, and fleets travel in wheeled flight cases.
Finished screen packages built on this cabinet — including pricing by pitch — are on our 500x500mm rental LED screen page, and fleet logistics work best when paired with proper transport cases for rental LED displays.
500x1000mm: Halving the Cabinet Count on Large Stage Walls
The 500x1000mm die-cast cabinet doubles the tile along one axis while keeping the same 500mm module grid. On a 10 x 5 m touring wall, that means roughly half the cabinets, half the lock operations and half the seam alignments compared with building the same area from 500x500mm units.
That is why productions that erect and strike large walls daily tend to standardize on this size: fewer mechanical operations per square meter directly reduces load-in time and wear on locks and handles. Resolution per cabinet follows the same pitch families as the 500x500mm version, scaled to the larger footprint.
For complete wide-format screen solutions and per-pitch pricing, see the 500x1000mm rental LED display page.
960x960mm Die-Cast Aluminum: The Outdoor High-Precision Cabinet
For permanent outdoor walls where seams, weight and service access all matter, our OK-series 960x960mm die-cast aluminum LED cabinet is the reference build. One cabinet covers 0.92 m² at just 77 mm deep and 28 kg (confirmed), with an all-aluminum structure and a finned center column that dissipates heat passively — no fans, no filter maintenance.
- Sealed both ways: IP65 on the front and rear faces (confirmed), so power and data compartments behind the modules survive driving rain as well as the display surface does.
- Front maintenance: the power box and modules are both serviced from the front (confirmed), letting the wall sit flush against a facade with no rear corridor.
- Flexible panel widths: the same chassis accepts 960 x 320, 960 x 640, 960 x 960 and 960 x 1280 mm panel formats (confirmed) to fine-tune screen proportions.
- Curves and creative shapes: a 40 x 320 mm module set angles to 80°, enabling arc walls and corners from the same cabinet family.
- Efficient power design: dual-voltage 3.2 V + 4.2 V supply keeps consumption at max 650 W/m² and average 250 W/m² (confirmed) — a real operating-cost lever on 24/7 billboards.
Each pitch maps to a fixed pixel grid per cabinet: P5.7 gives 168 x 168 pixels, P6.67 gives 144 x 144, P8 gives 120 x 120 and P10 gives 96 x 96 (confirmed, SMD2727 lamps). Multiply the grid across your array and you have the wall resolution that receiving cards and controllers must carry — our LED control system collection matches sending and receiving hardware to that number. A finished billboard built on this chassis is shown on the 960x960mm energy-saving A960 outdoor display page.
Fine Pitch Die-Cast Cabinets: 640x480mm, 600×337.5mm and 480x320mm
Indoor fine-pitch walls shrink the cabinet so seams disappear at two-meter viewing distance. Three formats cover the main use cases, each with a distinct mechanical trick:
- 640x480mm — the classic indoor fixed size for P1.2-P2.5 walls; four cabinets stack into a 1.28 x 0.96 m block (Illustrative arithmetic), keeping seam count low on control-room and meeting-room walls.
- 600×337.5mm — an exact 16:9 cabinet, so any array of them tiles 16:9 video without cropping; the format of choice for broadcast and command centers.
- 480x320mm — our most compact fixed chassis: 480 x 320 x 70 mm at about 3 kg per panel (confirmed, roughly 19 kg/m² — our spec sheet describes it as about 40% lighter than conventional designs). Modules from P1.25 to P4 (confirmed), a UL94 V-0 fireproof ABS shell, magnetic front access that lifts off “like one full module”, IP31 rating, and portrait orientation that curves inward for creative columns. Optional HOB treatment adds a transparent protective layer over the LEDs.
Which pitch suits which room depends on viewing distance; a typical fine-pitch build is walked through on our P2.5 indoor LED display page.
Why Rental Companies Choose Die-Cast Aluminum LED Cabinets
Rental fleets punish cabinet construction harder than any fixed installation: hundreds of build-strike cycles, truck loading, humid stages and outdoor festivals. Die-cast aluminum earns its standard status on four practical grounds:
One-Person Handling
At 7.2-7.5 kg per 500x500mm cabinet (confirmed), a single technician carries and locks panels overhead — smaller crews, faster load-ins, lower labor cost per show.
Weather Without Worry
Aluminum resists corrosion naturally, and our outdoor rental version seals IP65 front / IP43 rear (confirmed). Cabinets move from stage to festival site without rust management routines.
Seams Stay Tight
Cast frames resist the knocks and flex that open sheet-metal frames accumulate, so the wall still reads as one surface after seasons of touring.
Fleet Economics
Front-service modules cut show-day troubleshooting time, lock and handle parts are designed to be replaceable, and a straight, undamaged chassis holds resale value when the fleet turns over.
Die-Cast Aluminum vs Iron vs Magnesium Alloy LED Cabinets
Three castable materials trade weight against cost against corrosion behavior. Here is how they compare on the facts that drive purchase decisions, with verified figures where our spec sheets state them:
| Factor | Die-Cast Aluminum | Iron | Magnesium Alloy |
|---|---|---|---|
| Verified 960x960mm weight | 28 kg at 77 mm deep (confirmed) | Per design (our iron sizes: 22 kg at 640×960 / 45 kg at 1280×960, 95 mm deep) | 28 kg at 120 mm deep (confirmed) |
| Corrosion behavior | Naturally corrosion-resistant | Requires coating protection | Needs surface protection |
| Seam precision | High (precision casting) | Moderate (sheet fabrication) | High |
| Relative cabinet cost | Mid | Lowest | Highest |
| Typical IP rating (outdoor builds) | IP65 front and rear (confirmed, OK series) | IP65 front / IP55 rear (confirmed, DIP series) | IP65 (confirmed, B series) |
| Best for | Rental fleets, fine pitch, premium outdoor | Budget billboards, fixed advertising | Weight-critical structures, premium rental |
Weight and Handling: Planning Crew, Rigging and Transport
Cabinet weight scales into project totals faster than most buyers expect. The examples below are pure arithmetic from confirmed unit weights (Illustrative — add case tare, cabling and structure):
| Project (Illustrative) | Cabinet Grid | Cabinets | Total Cabinet Weight |
|---|---|---|---|
| 40 m² rental wall, 500x500mm | 16 x 10 | 160 | 160 x 7.5 kg = about 1,200 kg |
| 18.4 m² billboard, 960x960mm | 5 x 4 | 20 | 20 x 28 kg = 560 kg |
| 12.3 m² meeting wall, 480x320mm | 16 x 12 (portrait) | 192 | 192 x 3 kg = about 576 kg |
Three planning rules fall out of these numbers. Rental walls: at 7.5 kg per cabinet, one-person carry is realistic, but a 40 m² wall still moves over a tonne of aluminum — plan dollies and case routes, and remember flight cases pack typically six cabinets each with their own tare weight. Outdoor walls: at 28 kg per 960x960mm cabinet, use two-person carries or mechanical assistance, and pass the total wall weight to your structural engineer — AVIXA published standards are a useful reference for display installation practice. Fine pitch: the 3 kg panel is light, but 192 panels mean 192 connections to verify at commissioning — budget the labor, not just the weight.
When a Die-Cast Aluminum Cabinet Is NOT the Right Choice
We would rather quote the right material than the familiar one. Three situations call for a different cabinet:
- Lowest-budget permanent billboards: if the screen will never move and the structure already carries load, an iron cabinet delivers the same footprint at the lowest cost per square meter. The aluminum premium buys handling and corrosion resistance you may not need.
- Ultra-slim or custom-dimension signage: cast cabinets come in fixed grids. When the design demands a 40, 60 or 80 mm slim frame or a non-standard outline, extruded aluminum profile frames are the correct route — see the collection page for that material family.
- Absolute weight limits: where rigging capacity or floor loading decides the project, magnesium alloy achieves aluminum-class stiffness at lower density. It costs more and needs informed surface protection, which is a fair trade only when every kilogram counts.
Frequently Asked Questions About Die-Cast Aluminum LED Cabinets
Q1How much does a 500x500mm die-cast aluminum LED cabinet weigh?
Our die-cast rental cabinet weighs 7.2 kg in the indoor configuration and 7.5 kg outdoors (confirmed per the official specification sheet). The figure can shift slightly with module type and pitch, so confirm the exact weight for your configuration when ordering a fleet.
Q2How much does a 960x960mm die-cast aluminum LED cabinet weigh?
The OK-series 960x960mm die-cast aluminum cabinet weighs 28 kg at 77 mm depth (confirmed). Despite the weight it carries IP65 protection on both front and rear faces and supports front maintenance, so no rear service corridor is needed behind the wall.
Q3Which pixel pitches fit a 500x500mm die-cast cabinet?
Indoor versions run P2.604, P2.976 and P3.91 with 192 x 192, 168 x 168 and 128 x 128 pixels per cabinet; outdoor versions run P3.91 and P4.81 with 128 x 128 and 104 x 104 pixels (all confirmed). The outdoor version raises brightness to 4500 nits and sealing to IP65 front / IP43 rear.
Q4Can die-cast aluminum LED cabinets be powder coated?
Yes. Powder coating bonds well to die-cast aluminum and adds a color layer plus extra corrosion protection. Rental cabinets typically ship in matte black, while fixed-installation cabinets can be coated to match a facade or brand color — confirm available finishes and lead time for your order volume with our team.
Q5Does die-cast aluminum rust or corrode outdoors?
Aluminum does not rust the way iron does; it forms a natural oxide layer that protects the metal beneath. That is why die-cast aluminum cabinets suit coastal and humid sites, and why our OK series achieves IP65 on both faces without depending on paint alone. Iron cabinets, by contrast, rely on coating integrity for corrosion protection.
Q6Can a damaged die-cast aluminum cabinet be welded or repaired?
Aluminum castings can be welded by experienced technicians, but for rental fleets the faster route is usually replacement of designed-wear parts: locks, handles, seals and connector plates are specified as replaceable components. If a frame itself is cracked from impact, send us photos — we will advise whether repair or replacement is more economical.
Q7Die-cast aluminum vs iron LED cabinet: which should I choose?
Choose iron for permanently installed screens where budget leads — it is the lowest-cost cabinet per square meter and performs well when it never moves. Choose die-cast aluminum when cabinets are handled often, when corrosion resistance matters, or when seam precision is critical, as in rental fleets and fine-pitch walls.
Q8Die-cast aluminum vs magnesium alloy LED cabinet: what is the difference?
Both are castable and deliver high seam precision. Magnesium alloy has lower density, which our B series uses to hold a 960x960mm billboard cabinet at 28 kg (confirmed) — the same weight as our die-cast aluminum version but in a deeper 120 mm body designed for different pitch coverage. Magnesium costs more and needs informed surface protection; pick it when rigging or floor-load limits decide the project.
Q9How many die-cast aluminum cabinets do I need per square meter?
Divide one square meter by the cabinet area: 500x500mm gives 4 per m², 500x1000mm gives 2, 640x480mm about 3.26, 600×337.5mm about 4.94, 480x320mm about 6.51, and 960x960mm about 1.08. Multiply your screen area by the per-square-meter figure, then round to a whole tile grid.
Q10Do die-cast aluminum cabinets support front service or rear service?
Our die-cast range leans front-service: the 500x500mm rental cabinet offers module front maintenance in both indoor and outdoor versions, the OK series services power box and modules from the front, and the 480x320mm panel uses magnetic front access. Front service lets walls sit flush against facades; confirm the service direction of your chosen model before ordering.
Q11Can I order custom die-cast aluminum cabinet sizes?
Custom cast cabinets require new molds, so they only make sense at serious volume. For most custom dimensions the practical routes are trimming a standard tile grid or building the face from extruded aluminum profile frames, which reach slim depths such as 40, 60 or 80 mm. Send us the drawing and we will advise the shortest path.
Q12How are die-cast aluminum cabinets packed and shipped?
Rental fleets ship in wheeled flight cases, typically six 500x500mm cabinets per case, which protects the casting through repeated touring. Fixed-installation cabinets ship in individual cartons on pallets. We pack per your destination port and can quote DDP for many countries, so freight arrives ready for install.
Die-Cast Aluminum LED Cabinets, Summarized
Die casting turns aluminum into the cabinet that rental stages and fine-pitch walls default to: 7.2 kg per 500x500mm tile, 28 kg per 960x960mm outdoor panel, seams that stay invisible over years of handling. Check the size chart, verify the weight against your crew and structure, then let our engineers confirm the grid, resolution and material before you order.
Related reading: LED Display Cabinet Collection · Iron LED Cabinet Guide · Magnesium Alloy LED Cabinet Guide · 500x500mm Rental LED Screen · P2.5 Indoor LED Display · Modular LED Display System Guide