polycarbonate Seat Shells Vacuum Formed in 10 mm for Medical Equipment

These polycarbonate seat shells are thick gauge vacuum formed parts supplied to drawing for medical equipment. They are formed from polycarbonate sheet at 10 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
• Emi shielding coating 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
• dimension reports with every release

Typical applications

• monitor shrouds
• device trolleys
• dialysis machine covers
• imaging equipment panels
• seat shells used across general medical equipment builds

How it is made

1. Sheet is dried when the material needs it, then heated to forming temperature on the machine.
2. The part cools on a jig so the shape is held while the material stabilises.
3. Trimming is done on 5-axis routers or with a dedicated trim fixture to meet the drawing.
4. Parts are inspected, fitted with inserts or hardware if required, packed and shipped.
5. The sheet is formed over the mould with vacuum and, where the draw is deep, with plug assist.

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

• avoid sharp steps in the mould, which show as chill marks on the finished surface
• 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
• add ribs or returns instead of increasing sheet thickness to save weight and cycle time

Finishing and assembly options

• EMI shielding coating
• soft touch coating
• 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

Moulds, trim fixtures and programmes are stored against the part number, so a repeat order matches the first batch. First article inspection covers critical dimensions, wall thickness, colour and texture against the approved sample.

• dimension reports with every release
• ISO 9001 quality system
• material certificates with every batch

Packing and delivery

Each part is bagged, edges protected with foam, then cartonised for container loading. 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

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 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.