Plastic Enclosures PC/ASA in 5 mm for Fitness Equipment – Formed to Drawing

These PC/ASA plastic enclosures are thick gauge vacuum formed parts supplied to drawing for fitness equipment. They are formed from PC/ASA 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
• PC/ASA keeps the weight down while stiffness is held through the formed shape
• Anti graffiti 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
• ISO 9001 quality system

Typical applications

• seat shells
• console housings
• treadmill motor covers
• weight stack shrouds
• plastic enclosures used across general fitness 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. Tooling is cut: aluminium for production volumes, composite or printed moulds for samples and first articles.
3. The sheet is formed over the mould with vacuum and, where the draw is deep, with plug assist.
4. Sheet is dried when the material needs it, then heated to forming temperature on the machine.
5. Drawings are reviewed and a manufacturability report is issued with wall thickness, draft and radii marked up.

Material: PC/ASA

PC/ASA blends impact strength with weatherability, used for outdoor equipment covers that also need to survive knocks.

Design notes

• use corner radii of at least three times the sheet thickness to avoid thinning
• 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
• hold the draw ratio near 1:1 for deep parts, or specify plug assist

Finishing and assembly options

• anti graffiti coating
• UV stabilised as formed
• pad printed logos
• Threaded inserts, PEM fasteners and brackets fitted before dispatch
• Mating parts can be trial assembled before the first article ships

Quality

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

• ISO 9001 quality system
• food contact declarations available
• REACH compliant sheet available

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

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.

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.

Request a quotation

Send the drawing or a photo of the current plastic enclosures 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.