Custom Component Trays Thermoforming in ESD safe ABS for Water Treatment at 6 mm

Vacuum formed component trays are used across water treatment because they can be produced without the tooling spend of injection moulding and without the weight of sheet metal. This page covers how 6 mm ESD safe ABS sheet is formed for water treatment, 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 ESD safe ABS is the material most often specified for this combination.

Typical specification

Where these parts are used

• channel covers for water treatment
• filter housings for water treatment
• control panel shells for water treatment
• dosing tank liners for water treatment
• component trays in general water treatment 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: ESD safe ABS

ESD safe ABS keeps surface resistivity in the dissipative range, used for electronics carriers, tray systems and equipment covers in assembly areas.

Design tips for this part

• call out the finish on the drawing: mould texture, paint, or as-formed gloss
• plan the trim line on a flat face so the router can hold tolerance
• keep a draft angle of at least 3 degrees on vertical walls so the part releases cleanly
• avoid sharp steps in the mould, which show as chill marks on the finished surface
• hold the draw ratio near 1:1 for deep parts, or specify plug assist

Quality and inspection

Moulds, trim fixtures and programmes are stored against the part number, so a repeat order matches the first batch. First article inspection covers critical dimensions, wall thickness, colour and texture against the approved sample.

Cost and lead time

Tooling is the main cost driver at low volume, so a 6 mm component trays for water treatment 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 shorter lead time 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

What quantities make sense?

Vacuum forming pays off from roughly 25 pieces up to several thousand a year. Below that, printed or composite tooling keeps the setup cost low.

Do you supply certificates?

Material certificates, dimensional reports and flame retardancy or food contact declarations are issued with the shipment where the specification requires them.

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.

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.