TPO Tank Liners Vacuum Formed in 6 mm for Defence And Security Equipment

These TPO tank liners are thick gauge vacuum formed parts supplied to drawing for defence and security equipment. They are formed from TPO sheet at 6 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
• Silk screened markings 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
• PPAP or ISIR on request

Typical applications

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

How it is made

1. The part cools on a jig so the shape is held while the material stabilises.
2. Trimming is done on 5-axis routers or with a dedicated trim fixture to meet the drawing.
3. Drawings are reviewed and a manufacturability report is issued with wall thickness, draft and radii marked up.
4. Tooling is cut: aluminium for production volumes, composite or printed moulds for samples and first articles.
5. The sheet is formed over the mould with vacuum and, where the draw is deep, with plug assist.

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

• keep a draft angle of at least 3 degrees on vertical walls so the part releases cleanly
• plan the trim line on a flat face so the router can hold tolerance
• add ribs or returns instead of increasing sheet thickness to save weight and cycle time
• avoid sharp steps in the mould, which show as chill marks on the finished surface

Finishing and assembly options

• silk screened markings
• anti static coating
• UV stabilised as formed
• 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. Sheet thickness is checked on the formed part at the points shown on the drawing, and the readings go into the report.

• dimension reports with every release
• food contact declarations 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 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 tank liners 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.