How a Material Handling Builder Replaced an injection moulded part with Vacuum Formed Seat Shells in HDPE

This material handling project started with one question: could seat shells be vacuum formed instead of produced as an injection moulded part? The answer was yes at 4 mm HDPE, and the part went from drawing to approved sample in 5 weeks. Here is the route and the result.

The starting point

• Part: seat shells for material handling
• Existing route: an injection moulded part
• Annual volume: 3600 pieces
• Problems: high unit cost, long lead time, and variation between batches

What was wrong with the old route

The previous injection moulded part needed several operations to reach finished shape, and every operation added both cost and a chance for variation. Weight was higher than it needed to be, and design changes meant new fixtures each time. For a programme of 3600 pieces a year that is a poor fit.

What we built

Process route

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

Results

• reduced noise by 6 dB
• First article approved in 5 weeks
• Tooling amortised inside the first production batch
• Repeat releases match the approved sample: tooling and programmes are stored against the part number
• 3600 pieces shipped to date with no dimensional escapes

Lessons from this project

• The 4 mm was set from the load case, which avoided over specifying the sheet and paying for weight that was not needed
• Draft and radii were checked before the tool was cut, so the first sample released without hand work
• The trim line was placed on a flat face, which kept the router inside ±0.2 mm
• Tooling and programmes are stored against the part number, so repeat releases need no new proving run

What the client said

“The sample arrived on the date we were given and it fitted the assembly on the first try. The seat shells is lighter than the part it replaced and the finish holds up in the field. We now release the seat shells against stored tooling and the paperwork comes with the shipment.”

Frequently asked questions

Could the same route work on a different part?

If the part is a shell, cover, tray or enclosure between 1.5 mm and 12 mm thick, it is almost always worth quoting. Send the drawing and the answer comes back with a material and a tooling plan.

How is the tooling handled between orders?

Tooling, trim fixtures and programmes are kept against the part number for the life of the programme, so a repeat release needs no new proving run.

Next step

Send the drawing or the existing seat shells with the annual quantity. The reply is a manufacturability review, a material recommendation and a quotation within 24 hours.