Carry Cases polycarbonate in 4 mm for Defence And Security Equipment – Formed to Drawing

These polycarbonate carry cases are thick gauge vacuum formed parts supplied to drawing for defence and security equipment. They are formed from polycarbonate sheet at 4 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
• Two coat polyurethane paint 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

• transport trays
• antenna covers
• console covers
• case shells
• carry cases used across general defence and security equipment 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. Tooling is cut: aluminium for production volumes, composite or printed moulds for samples and first articles.
4. The sheet is formed over the mould with vacuum and, where the draw is deep, with plug assist.
5. The part cools on a jig so the shape is held while the material stabilises.

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

• keep a draft angle of at least 3 degrees on vertical walls so the part releases cleanly
• call out the finish on the drawing: mould texture, paint, or as-formed gloss
• 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

Finishing and assembly options

• two coat polyurethane paint
• soft touch coating
• hot stamped accents
• 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. Sheet thickness is checked on the formed part at the points shown on the drawing, and the readings go into the report.

• UL94 V-0 grades available
• food contact declarations available
• 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 10–15 working days, and repeat releases ship against stored tooling without a new proving run.

Frequently asked questions

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.

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.

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.

Request a quotation

Send the drawing or a photo of the current carry cases 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.