Component Trays polycarbonate in 5 mm for Aerospace Interiors – Formed to Drawing

These polycarbonate component trays are thick gauge vacuum formed parts supplied to drawing for aerospace interiors. They are formed from polycarbonate sheet at 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
• polycarbonate keeps the weight down while stiffness is held through the formed shape
• Matte finish 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
• material certificates with every batch

Typical applications

• stowage bin trays
• galley liners
• seat back shells
• lavatory panels
• component trays used across general aerospace interiors 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. 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. Sheet is dried when the material needs it, then heated to forming temperature on the machine.

Material: polycarbonate

Polycarbonate is used when the housing must survive impact or carry a glazing function. It must be dried before forming or the sheet will bubble.

Design notes

• add ribs or returns instead of increasing sheet thickness to save weight and cycle time
• call out the finish on the drawing: mould texture, paint, or as-formed gloss
• use corner radii of at least three times the sheet thickness to avoid thinning
• avoid sharp steps in the mould, which show as chill marks on the finished surface

Finishing and assembly options

• matte finish
• as formed gloss
• two coat polyurethane paint
• Threaded inserts, PEM fasteners and brackets fitted before dispatch
• Mating parts can be trial assembled before the first article ships

Quality

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

• ISO 9001 quality system
• PPAP or ISIR on request
• food contact declarations available

Packing and delivery

Parts are nested to save freight, with returnable dunnage available on repeat routes. 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

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.

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.

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 component trays 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.