TPO Battery Boxes Vacuum Formed in 2 mm for Vending And Kiosk

These TPO battery boxes are thick gauge vacuum formed parts supplied to drawing for vending and kiosk. They are formed from TPO sheet at 2 mm, trimmed on 5-axis routers and inspected against the drawing before packing. Buyers choose this route where a metal fabrication is too heavy, or where injection moulding tooling cannot be justified for the volume.

Product specification

Key features

• One piece shell replaces a fabrication, so assembly hours drop
• TPO keeps the weight down while stiffness is held through the formed shape
• As formed gloss finish as standard, further finishes on request
• Trimmed on 5-axis routers, so mounting holes and cut outs match the drawing
• Tooling stored against the part number for repeat and spare orders
• PPAP or ISIR on request

Typical applications

• product trays
• coin module covers
• dispenser housings
• machine front panels
• battery boxes used across general vending and kiosk builds

How it is made

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

Material: TPO

TPO sheet is used where the part lives outdoors: it stays flexible in the cold and resists UV without a coating.

Design notes

• hold the draw ratio near 1:1 for deep parts, or specify plug assist
• add ribs or returns instead of increasing sheet thickness to save weight and cycle time
• 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

Finishing and assembly options

• as formed gloss
• mould texture
• clear protective film
• Threaded inserts, PEM fasteners and brackets fitted before dispatch
• Mating parts can be trial assembled before the first article ships

Quality

Moulds, trim fixtures and programmes are stored against the part number, so a repeat order matches the first batch. Sheet thickness is checked on the formed part at the points shown on the drawing, and the readings go into the report.

• dimension reports with every release
• UL94 V-0 grades available
• PPAP or ISIR on request

Packing and delivery

Each part is bagged, edges protected with foam, then cartonised for container loading. Standard lead time to first article is 3–4 weeks, and repeat releases ship against stored tooling without a new proving run.

Frequently asked questions

What quantity can I order?

Sample quantities start at one piece off printed tooling. The process pays back from about 25 pieces a year and runs well into several thousand.

Are spare parts available later?

Tooling is stored against the part number for the life of the programme, so replacements or spare panels can be released at any time.

Can you make it in another material?

Any grade in this family can be swapped in. Send the requirement and the material will be quoted with the price difference shown.

Request a quotation

Send the drawing or a photo of the current battery boxes with the quantity and the finish required. The reply covers material choice, wall thickness, tooling route and price, so the decision is made on a complete picture.