Thick Gauge ASA Cable Covers in 6 mm – Ev Charging Range

These ASA cable covers are thick gauge vacuum formed parts supplied to drawing for EV charging. They are formed from ASA 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
• ASA 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
• PPAP or ISIR on request

Typical applications

• cable management panels
• charger housings
• payment terminal bezels
• wallbox covers
• cable covers used across general EV charging builds

How it is made

1. The part cools on a jig so the shape is held while the material stabilises.
2. Tooling is cut: aluminium for production volumes, composite or printed moulds for samples and first articles.
3. Sheet is dried when the material needs it, then heated to forming temperature on the machine.
4. Drawings are reviewed and a manufacturability report is issued with wall thickness, draft and radii marked up.
5. The sheet is formed over the mould with vacuum and, where the draw is deep, with plug assist.

Material: ASA

ASA keeps its colour and surface under UV better than ABS, which suits outdoor covers that are not painted.

Design notes

• 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
• plan the trim line on a flat face so the router can hold tolerance
• add ribs or returns instead of increasing sheet thickness to save weight and cycle time

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

Batch releases carry a dimensional report, material certificate and, where agreed, PPAP or ISIR documentation. First article inspection covers critical dimensions, wall thickness, colour and texture against the approved sample.

• food contact declarations available
• REACH compliant sheet available
• 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

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.

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.

Request a quotation

Send the drawing or a photo of the current cable covers 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.