OEM Component Trays Vacuum Forming Service in PMMA acrylic for Laboratory Instruments Builders at 10 mm

Vacuum formed component trays are used across laboratory instruments because they can be produced without the tooling spend of injection moulding and without the weight of sheet metal. This page covers how 10 mm PMMA acrylic sheet is formed for laboratory instruments, what tolerances are realistic, and what has to be on the drawing before tooling starts.

The route below is the one used for most of the component trays shipped from this plant: sheet is heated on the forming machine, drawn over an aluminium or composite mould, cooled on a jig, then trimmed on a 5-axis router. For component trays the sheet gauge is selected from the load case rather than from habit, and PMMA acrylic is the material most often specified for this combination.

Typical specification

Where these parts are used

• fume hood liners for laboratory instruments
• instrument covers for laboratory instruments
• sample tray systems for laboratory instruments
• analyser housings for laboratory instruments
• component trays in general laboratory instruments builds

How the part is made

1. Drawings are reviewed and a manufacturability report is issued with wall thickness, draft and radii marked up.
2. Tooling is cut: aluminium for production volumes, composite or printed moulds for samples and first articles.
3. Sheet is dried when the material needs it, then heated to forming temperature on the machine.
4. The sheet is formed over the mould with vacuum and, where the draw is deep, with plug assist.
5. The part cools on a jig so the shape is held while the material stabilises.
6. Trimming is done on 5-axis routers or with a dedicated trim fixture to meet the drawing.
7. Parts are inspected, fitted with inserts or hardware if required, packed and shipped.

Material notes: PMMA acrylic

PMMA gives the glossiest surface and the best UV stability, which is why it is used for light housings and outdoor sign faces.

Design tips for this part

• add ribs or returns instead of increasing sheet thickness to save weight and cycle time
• keep a draft angle of at least 3 degrees on vertical walls so the part releases cleanly
• hold the draw ratio near 1:1 for deep parts, or specify plug assist
• plan the trim line on a flat face so the router can hold tolerance
• call out the finish on the drawing: mould texture, paint, or as-formed gloss

Quality and inspection

First article inspection covers critical dimensions, wall thickness, colour and texture against the approved sample. Sheet thickness is checked on the formed part at the points shown on the drawing, and the readings go into the report.

Cost and lead time

Tooling is the main cost driver at low volume, so a 10 mm component trays for laboratory instruments is usually quoted with a composite or printed mould first and the aluminium tool cut once the design is frozen. That keeps the first article cost low and gives a real part to test before the production tool exists. The result is lighter weight compared with the alternatives, and a piece price that stays stable across repeat releases.

• Sample tooling: 7–15 working days
• Production tooling: 3–4 weeks
• Repeat orders run on stored tooling with no new proving run

Frequently asked questions

How long does tooling take?

Sample and first article tooling is usually cut in 7 to 15 working days. Production aluminium tools take 3 to 4 weeks depending on size and cooling layout.

What do you need to quote?

A 3D file or drawing, the material if it is fixed, the annual quantity and the finish. Photos of the current part are enough for a first estimate.

Can you match an existing part?

Yes. Send a sample or scan and the part can be reverse engineered, with the wall thickness and material measured from the sample.

Getting started

Send the drawing or a photo of the current component trays with the quantity and the finish. The first reply is a manufacturability review with the wall thickness, material and a quotation, so the decision is made on facts rather than on a price alone.