PC/ASA Carry Cases Vacuum Formed in 5 mm for Playground Equipment

These PC/ASA carry cases are thick gauge vacuum formed parts supplied to drawing for playground 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
• 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
• food contact declarations available

Typical applications

• climbing tower caps
• seat buckets
• panel covers
• slide shells
• carry cases used across general playground 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. Sheet is dried when the material needs it, then heated to forming temperature on the machine.
3. Tooling is cut: aluminium for production volumes, composite or printed moulds for samples and first articles.
4. The part cools on a jig so the shape is held while the material stabilises.
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

• call out the finish on the drawing: mould texture, paint, or as-formed gloss
• hold the draw ratio near 1:1 for deep parts, or specify plug assist
• 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

Finishing and assembly options

• hot stamped accents
• silk screened markings
• anti static coating
• 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.

• dimension reports with every release
• UL94 V-0 grades available
• material certificates with every batch

Packing and delivery

Large panels are crated in made to measure wooden cases with corner protection. Standard lead time to first article is 3–4 weeks, 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 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.