Click Image to Enlarge Precision Thermoforming of a Plastic Air Conditioner Cover for a Mass Transit Application

We have many years of experience thermoforming durable plastic components that stand up to outdoor use while maintaining their like-new appearance. The resilient plastic cover pictured here is used to cover both the front and rear air conditioners located on top of a transit vehicle. We chose a thermoplastic polyolefin (TPO) material that would provide a high gloss, smooth finish which would not degrade from UV exposure. Well-executed tooling and our large format rotary thermoformer enabled us to run high volume production of these 51” x 105” x 5” parts while maintaining the outsized dimensions consistently and repeatedly. We drill and trim the formed parts using our precision 5-axis CNC, all the while maintaining a tolerance of ±.010” on all features and dimensions.

Quality is important to us and the stringent procedures in our ISO 9001:2008 certified quality program ensured that this product was on specification and would remain wear-resistant and cosmetically appealing over an extended service life. For more information on our thermoforming process or how our services can improve your next application contact us today.

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Precision Thermoforming of a Plastic Air Conditioner Cover Project Highlights

Product Description

Mass Transit Vehicle Air Conditioner Cover

Precision Thermoforming Capabilities Applied/Processes

CNC Machining
Ordinary cleaning and prepping for shipment

Equipment Used to Manufacture Part

Large Rotary Thermoformer
5-Axis CNC


Plastic Fabrication
Steel Fabrication

Overall Part Dimensions

51.0” wide x 105.0” long x 5.0” high

Tightest Tolerances

+/- 0.010” on hole spacing, OAH and OAL

Material Used

TPO (Thermoplastic Polyolefin Material)

Material Finish

High-gloss…smooth finish

Additional Facts

Highly critical part from a cosmetic standpoint

In process testing/inspection performed

Standard ISO 9001-2008 procedures are followed

Industry for Use

Transportation Industry


Large Volumes

Delivery/Turnaround Time

Six (6) weeks tooling and Parts

Delivery Location


Standards Met

Customer Specifications, 2D CAD Drawing

Product Name

Air Conditioner Cover