food grade polypropylene Battery Boxes Vacuum Formed in 6 mm for Motorcycle And Scooter

These food grade polypropylene battery boxes are thick gauge vacuum formed parts supplied to drawing for motorcycle and scooter. They are formed from food grade polypropylene sheet at 6 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
• food grade polypropylene keeps the weight down while stiffness is held through the formed shape
• Pad printed logos 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
• REACH compliant sheet available

Typical applications

• side covers
• fairing panels
• windscreen mounts
• top box shells
• battery boxes used across general motorcycle and scooter builds

How it is made

1. The sheet is formed over the mould with vacuum and, where the draw is deep, with plug assist.
2. Trimming is done on 5-axis routers or with a dedicated trim fixture to meet the drawing.
3. Sheet is dried when the material needs it, then heated to forming temperature on the machine.
4. Drawings are reviewed and a manufacturability report is issued with wall thickness, draft and radii marked up.
5. The part cools on a jig so the shape is held while the material stabilises.

Material: food grade polypropylene

Food grade polypropylene is used for trays, hoppers and liners that touch product, and it can be washed with caustic cleaners.

Design notes

• avoid sharp steps in the mould, which show as chill marks on the finished surface
• 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
• hold the draw ratio near 1:1 for deep parts, or specify plug assist

Finishing and assembly options

• pad printed logos
• as formed gloss
• anti graffiti coating
• Threaded inserts, PEM fasteners and brackets fitted before dispatch
• Mating parts can be trial assembled before the first article ships

Quality

First article inspection covers critical dimensions, wall thickness, colour and texture against the approved sample. Batch releases carry a dimensional report, material certificate and, where agreed, PPAP or ISIR documentation.

• food contact declarations available
• ISO 9001 quality system
• RoHS compliant grades available

Packing and delivery

Large panels are crated in made to measure wooden cases with corner protection. 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.

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.

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.

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.