Folded Electrical Junction Boxes and Associated Methods of Use and Manufacture

A method for manufacturing an electrical junction box, comprising:

• receiving a single sheet or roll of metal;
• initiating a plurality of operations to form at least two electrical junction boxes or accessories from the single sheet or roll of metal, wherein the operations comprise:
• forming at least one extruded threaded hole in a wall of one of the boxes or accessories, wherein the extruded threaded hole comprises an extruded threaded ground bump;
• cutting the sheet or roll of metal to form a plurality of walls for the boxes or accessories;
• scoring a centerline in at least one surface of one of the boxes or accessories;
• and
• cutting at least one knockout in at least one wall of one of the boxes or accessories, wherein the at least one knockout comprises two or three concentrically or eccentrically aligned knockouts;
• forming at least one protrusion in one wall of at least one box or accessory and a corresponding indentation in an adjacent wall of the at least one box or accessory, wherein the at least one protrusion and corresponding indentation can be aligned in substantial contact with each other when the one wall overlaps the adjacent wall;
• and
• folding the plurality of walls to form at least one folded electrical junction box or accessory.

A system for manufacturing an electrical junction box or accessory, comprising:

• a station operable to receive a single sheet or roll of metal;
• a plurality of stations operable to initiate a plurality of operations to form at least two electrical junction boxes or accessories from the single sheet of metal, wherein the operations comprise:
• forming at least one extruded threaded hole in a wall of one of the boxes or accessories;
• cutting the sheet or roll of metal to form a plurality of walls for the boxes or accessories;
• scoring a centerline in at least one surface of one of the boxes or accessories;
• and
• cutting at least one knockout in at least one wall of one of the boxes or accessories;
• and
• a station operable to fold the plurality of walls to form at least one folded electrical junction box or accessory.