Thick Gauge HDPE Instrument Bezels in 1.5 mm – Ev Charging Range

These HDPE instrument bezels are thick gauge vacuum formed parts supplied to drawing for EV charging. They are formed from HDPE 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
• HDPE keeps the weight down while stiffness is held through the formed shape
• Uv stabilised as formed 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
• ISO 9001 quality system

Typical applications

• cable management panels
• charger housings
• payment terminal bezels
• wallbox covers
• instrument bezels used across general EV charging 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. Sheet is dried when the material needs it, then heated to forming temperature on the machine.
3. Tooling is cut: aluminium for production volumes, composite or printed moulds for samples and first articles.
4. Parts are inspected, fitted with inserts or hardware if required, packed and shipped.
5. Drawings are reviewed and a manufacturability report is issued with wall thickness, draft and radii marked up.

Material: HDPE

HDPE is chosen for chemical resistance and impact strength at low temperature. It needs more heat and a longer cooling cycle than ABS, and it is painted only after flame or plasma treatment.

Design notes

• avoid sharp steps in the mould, which show as chill marks on the finished surface
• plan the trim line on a flat face so the router can hold tolerance
• 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

Finishing and assembly options

• UV stabilised as formed
• as formed gloss
• EMI shielding coating
• 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. Batch releases carry a dimensional report, material certificate and, where agreed, PPAP or ISIR documentation.

• food contact declarations available
• material certificates with every batch
• REACH compliant sheet available

Packing and delivery

Parts are nested to save freight, with returnable dunnage available on repeat routes. Standard lead time to first article is 2–3 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.

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.

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 instrument bezels 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.