12 mm polycarbonate Cowls Manufacturer for Rail Transit Interiors

These polycarbonate cowls are thick gauge vacuum formed parts supplied to drawing for rail transit interiors. They are formed from polycarbonate sheet at 12 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
• Anti static 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
• REACH compliant sheet available

Typical applications

• wall panels
• luggage rack trays
• ceiling end caps
• seat shells
• cowls used across general rail transit interiors builds

How it is made

1. Trimming is done on 5-axis routers or with a dedicated trim fixture to meet the drawing.
2. Parts are inspected, fitted with inserts or hardware if required, packed and shipped.
3. The sheet is formed over the mould with vacuum and, where the draw is deep, with plug assist.
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
• use corner radii of at least three times the sheet thickness to avoid thinning
• hold the draw ratio near 1:1 for deep parts, or specify plug assist
• keep a draft angle of at least 3 degrees on vertical walls so the part releases cleanly

Finishing and assembly options

• anti static coating
• clear protective film
• hot stamped accents
• 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. Sheet thickness is checked on the formed part at the points shown on the drawing, and the readings go into the report.

• REACH compliant sheet available
• dimension reports with every release
• PPAP or ISIR on request

Packing and delivery

Each part is bagged, edges protected with foam, then cartonised for container loading. Standard lead time to first article is 7–15 working days, 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.

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.

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 cowls 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.