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A customer in the transportation industry contracted us to fabricate a custom truck topper. Opting for a lightweight thermoformable material (ASA) allowed us to replace a much heavier thermoplastic material without sacrificing performance.

We designed and fabricated custom production molds and fixtures for part production and fabricated the unit with high impact weatherable. Our highly developed thermoforming process was employed for manufacturing, completing the precision detailing with CNC machining processes to tolerances of ± 0.010”. The part was then assembled on site to specification.

Overall dimensions of the finished unit were 124” in length, 80” in width, and 27” in height with part thickness ranging from 0.170” to 0.250”. The part weighed 220 lbs. and exhibited a smooth finish of various colors. Turnaround time was 6 to 8 weeks, and the product was made available for nationwide shipping.

Specialized packaging (welded steel) was also created for this product. The production was a success on all levels meeting customer and rigorous industry standards. Budget and delivery times were met along with achieving internal goals of cost containment and providing a better and lighter product. As industry leaders in the truck and trailer manufacturing industry, Our precision metal stamping is ever improving and constantly innovating our processes and product offerings. For more details about this truck topper fabrication process or our other recognized custom manufacturing capabilities please see the table below or contact us directly.

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Fabrication of an ABS Truck Cap/Topper Project Highlights

Product Description

Truck Topper

Capabilities Applied/Processes

Mold & Fixture Fabrication
CNC Machining

Overall Part Dimensions

Product Length: 124″
Product Width: 80″
Product Height: 27″
Product Weight: 220 lbs.

Tightest Tolerances

± 0.010″

Material Used

High Impact Weatherable ABS – ASA

  • Material Thickness: 0.170″ – 0.250″
Material Finish

Smooth Finish
Color: Various

Special Feature

Custom Made Packaging
Made of Welded Steel

In process testing/inspection performed

Dimensional Inspection, Visual Inspection, Fit Test

Industry for Use



Large Volume

Delivery/Turnaround Time

6 – 8 Weeks

Delivery Location

USA – Nationwide

Standards Met

Customer Specifications, 2D CAD Drawing
ISO 9001:2008

Product Name

Truck Cap/Topper