recycled HDPE Seat Shells Vacuum Formed in 4 mm for Truck And Bus

These recycled HDPE seat shells are thick gauge vacuum formed parts supplied to drawing for truck and bus. They are formed from recycled HDPE sheet at 4 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
• Anti graffiti coating 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
• material certificates with every batch

Typical applications

• engine tunnel covers
• stepwell panels
• interior trim panels
• bunk liners
• seat shells used across general truck and bus builds

How it is made

1. Trimming is done on 5-axis routers or with a dedicated trim fixture to meet the drawing.
2. Parts are inspected, fitted with inserts or hardware if required, packed and shipped.
3. Sheet is dried when the material needs it, then heated to forming temperature on the machine.
4. The sheet is formed over the mould with vacuum and, where the draw is deep, with plug assist.
5. Drawings are reviewed and a manufacturability report is issued with wall thickness, draft and radii marked up.

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

• keep a draft angle of at least 3 degrees on vertical walls so the part releases cleanly
• 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
• use corner radii of at least three times the sheet thickness to avoid thinning

Finishing and assembly options

• anti graffiti coating
• silk screened markings
• 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.

• material certificates with every batch
• RoHS compliant grades available
• UL94 V-0 grades available

Packing and delivery

Parts are stacked with interleaved film and packed in export cartons on pallets. 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.

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 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.