Thick Gauge ABS/PC Display Shells in 5 mm – Marine And Boat Building Range

These ABS/PC display shells are thick gauge vacuum formed parts supplied to drawing for marine and boat building. They are formed from ABS/PC 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
• ABS/PC keeps the weight down while stiffness is held through the formed shape
• Powder coat 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
• RoHS compliant grades available

Typical applications

• seat bases
• battery box liners
• hatch covers
• console shells
• display shells used across general marine and boat building builds

How it is made

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

Material: ABS/PC

ABS/PC carries higher heat resistance than ABS alone, which matters for housings around motors, drives and power electronics.

Design notes

• avoid sharp steps in the mould, which show as chill marks on the finished surface
• hold the draw ratio near 1:1 for deep parts, or specify plug assist
• plan the trim line on a flat face so the router can hold tolerance
• call out the finish on the drawing: mould texture, paint, or as-formed gloss

Finishing and assembly options

• powder coat finish
• hot stamped accents
• EMI shielding coating
• 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.

• material certificates with every batch
• RoHS compliant grades available
• PPAP or ISIR on request

Packing and delivery

Parts are stacked with interleaved film and packed in export cartons on pallets. 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.

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.

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 display 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.