2 mm recycled HDPE Equipment Covers Manufacturer for Fitness Equipment

These recycled HDPE equipment covers are thick gauge vacuum formed parts supplied to drawing for fitness equipment. They are formed from recycled HDPE 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
• recycled HDPE keeps the weight down while stiffness is held through the formed shape
• Pad printed logos 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

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

How it is made

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

Material: recycled HDPE

Recycled HDPE sheet lowers material cost and supports sustainability targets, with mechanical properties close to virgin sheet for non critical parts.

Design notes

• call out the finish on the drawing: mould texture, paint, or as-formed gloss
• plan the trim line on a flat face so the router can hold tolerance
• 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

Finishing and assembly options

• pad printed logos
• matte finish
• soft touch coating
• 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. Moulds, trim fixtures and programmes are stored against the part number, so a repeat order matches the first batch.

• dimension reports with every release
• material certificates with every batch
• PPAP or ISIR on request

Packing and delivery

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

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 equipment 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.