OEM Seat Shells polypropylene in 1.5 mm for Material Handling

These polypropylene seat shells are thick gauge vacuum formed parts supplied to drawing for material handling. They are formed from polypropylene sheet at 1.5 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
• polypropylene keeps the weight down while stiffness is held through the formed shape
• Silk screened markings 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
• food contact declarations available

Typical applications

• pallet tops
• tote liners
• conveyor covers
• picker truck panels
• seat shells used across general material handling builds

How it is made

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. The part cools on a jig so the shape is held while the material stabilises.
4. Trimming is done on 5-axis routers or with a dedicated trim fixture to meet the drawing.
5. The sheet is formed over the mould with vacuum and, where the draw is deep, with plug assist.

Material: polypropylene

Polypropylene survives repeated impact and most cleaning chemicals. Its low forming temperature keeps cycles short, but it shrinks more, so the mould is cut with the shrink factor built in.

Design notes

• hold the draw ratio near 1:1 for deep parts, or specify plug assist
• use corner radii of at least three times the sheet thickness to avoid thinning
• keep a draft angle of at least 3 degrees on vertical walls so the part releases cleanly
• plan the trim line on a flat face so the router can hold tolerance

Finishing and assembly options

• silk screened markings
• hot stamped accents
• UV stabilised as formed
• Threaded inserts, PEM fasteners and brackets fitted before dispatch
• Mating parts can be trial assembled before the first article ships

Quality

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

• RoHS compliant grades available
• REACH compliant sheet available
• UL94 V-0 grades available

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

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.

How fast is the first article?

Seven to fifteen working days from drawing release for sample tooling, with production tooling in three to four weeks.

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.

Request a quotation

Send the drawing or a photo of the current seat shells 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.