ABS/PC Door Panels Vacuum Formed in 6 mm for Playground Equipment

These ABS/PC door panels are thick gauge vacuum formed parts supplied to drawing for playground equipment. They are formed from ABS/PC sheet at 6 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
• ABS/PC keeps the weight down while stiffness is held through the formed shape
• Clear protective film 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

• climbing tower caps
• panel covers
• slide shells
• seat buckets
• door panels used across general playground equipment builds

How it is made

1. Tooling is cut: aluminium for production volumes, composite or printed moulds for samples and first articles.
2. Drawings are reviewed and a manufacturability report is issued with wall thickness, draft and radii marked up.
3. Sheet is dried when the material needs it, then heated to forming temperature on the machine.
4. Trimming is done on 5-axis routers or with a dedicated trim fixture to meet the drawing.
5. The part cools on a jig so the shape is held while the material stabilises.

Material: ABS/PC

ABS/PC carries higher heat resistance than ABS alone, which matters for housings around motors, drives and power electronics.

Design notes

• add ribs or returns instead of increasing sheet thickness to save weight and cycle time
• keep a draft angle of at least 3 degrees on vertical walls so the part releases cleanly
• avoid sharp steps in the mould, which show as chill marks on the finished surface
• use corner radii of at least three times the sheet thickness to avoid thinning

Finishing and assembly options

• clear protective film
• powder coat finish
• matte finish
• 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
• REACH compliant sheet available
• UL94 V-0 grades 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

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.

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 door panels 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.