I am working on a project that uses 120VAC power. I have made a lot of enclosures for low voltage projects in the past, but this is my first high voltage project that needs an enclosure.
I am wondering what my options are, and what precautions I need to take to ensure my project is safe.
Ideally I would like to use a powder coated aluminum enclosure, as it matches the aesthetics of my past projects and also because I have a supplier that can do machining / uv printing at an affordable rate (enclosure prices elsewhere have generally been exorbitant, or require that I do all the machining / graphical work by hand). I want to check that this is safe and ask what precautions I should take before designing my project around this process.
Is aluminum safe? If so, should I ground the chassis? Are there other precautions that I need to be aware of?
The power input of my project is a 10A rated IEC socket, but I will likely fuse the project at 5A, in case that information is relevant.