4 mm polycarbonate Splash Guards Manufacturer for Fitness Equipment

These polycarbonate splash guards are thick gauge vacuum formed parts supplied to drawing for fitness 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
• Hot stamped accents 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

• treadmill motor covers
• console housings
• weight stack shrouds
• seat shells
• splash guards used across general fitness equipment builds

How it is made

1. Sheet is dried when the material needs it, then heated to forming temperature on the machine.
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. Trimming is done on 5-axis routers or with a dedicated trim fixture to meet the drawing.
5. Tooling is cut: aluminium for production volumes, composite or printed moulds for samples and first articles.

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

Finishing and assembly options

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

• RoHS compliant grades available
• PPAP or ISIR on request
• REACH compliant sheet available

Packing and delivery

Large panels are crated in made to measure wooden cases with corner protection. 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

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.

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 splash guards 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.