2 mm ASA Light Housings Manufacturer for Defence And Security Equipment

These ASA light housings are thick gauge vacuum formed parts supplied to drawing for defence and security equipment. They are formed from ASA sheet at 2 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
• Uv stabilised as formed 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
• RoHS compliant grades available

Typical applications

• case shells
• transport trays
• antenna covers
• console covers
• light housings used across general defence and security equipment builds

How it is made

1. Sheet is dried when the material needs it, then heated to forming temperature on the machine.
2. The part cools on a jig so the shape is held while the material stabilises.
3. Parts are inspected, fitted with inserts or hardware if required, packed and shipped.
4. Trimming is done on 5-axis routers or with a dedicated trim fixture to meet the drawing.
5. Drawings are reviewed and a manufacturability report is issued with wall thickness, draft and radii marked up.

Material: ASA

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

Design notes

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

• UV stabilised as formed
• two coat polyurethane paint
• hot stamped accents
• Threaded inserts, PEM fasteners and brackets fitted before dispatch
• Mating parts can be trial assembled before the first article ships

Quality

Sheet thickness is checked on the formed part at the points shown on the drawing, and the readings go into the report. Moulds, trim fixtures and programmes are stored against the part number, so a repeat order matches the first batch.

• food contact declarations available
• material certificates with every batch
• dimension reports with every release

Packing and delivery

Each part is bagged, edges protected with foam, then cartonised for container loading. 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

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.

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.

Request a quotation

Send the drawing or a photo of the current light housings 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.