Thick Gauge TPO Seat Shells in 5 mm – Motorcycle And Scooter Range

These TPO seat shells are thick gauge vacuum formed parts supplied to drawing for motorcycle and scooter. They are formed from TPO 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
• TPO keeps the weight down while stiffness is held through the formed shape
• Mould texture 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
• ISO 9001 quality system

Typical applications

• side covers
• fairing panels
• windscreen mounts
• top box shells
• seat shells used across general motorcycle and scooter 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. Parts are inspected, fitted with inserts or hardware if required, packed and shipped.

Material: TPO

TPO sheet is used where the part lives outdoors: it stays flexible in the cold and resists UV without a coating.

Design notes

• 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
• call out the finish on the drawing: mould texture, paint, or as-formed gloss
• keep a draft angle of at least 3 degrees on vertical walls so the part releases cleanly

Finishing and assembly options

• mould texture
• pad printed logos
• two coat polyurethane paint
• Threaded inserts, PEM fasteners and brackets fitted before dispatch
• Mating parts can be trial assembled before the first article ships

Quality

Moulds, trim fixtures and programmes are stored against the part number, so a repeat order matches the first batch. Batch releases carry a dimensional report, material certificate and, where agreed, PPAP or ISIR documentation.

• RoHS compliant grades available
• PPAP or ISIR on request
• REACH compliant sheet available

Packing and delivery

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

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 seat shells 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.