EV battery housing covers
Deep-drawn FR covers and CCS trays for EV battery packs and BESS modules.
Durable · Versatile · up to 12 mm
Thick gauge thermoforming & fabrication solutions
Thick gauge thermoforming (also called heavy gauge thermoforming) is the go-to process for creating durable, large, and complex plastic components. Using thermoplastic sheets typically ranging from 2 mm to 12 mm, this process delivers robust, rigid, high-performance parts for automotive, aerospace, industrial equipment, medical devices, consumer products, and transportation. Unlike thin gauge packaging, thick gauge thermoforming produces structural and reusable components that often replace metal, fiberglass, or injection-moulded parts — a lightweight yet durable alternative.
Get a Quote Now!Key benefits
Strength & durability
Produces robust parts with excellent impact resistance and long service life.
Large part capability
Ideal for oversized panels and structural components — formed on the largest thermoforming bed in India.
Lower tooling cost
Significantly cheaper tooling than injection moulding, especially for mid-volume runs.
Design freedom
Enables complex shapes, deep draws, and large surface areas.
UV & FR options
Available with UV-resistant and flame-retardant grades for outdoor and safety-critical use.
Lightweight alternative
Replaces metal and fiberglass while reducing weight and cost.
Wide industry reach
Trusted in automotive, aerospace, medical, industrial, marine, and consumer goods.
Common applications
Automotive & transportation
- Dashboards & interior trim panels
- Bumpers & wheel arch liners
- Underbody shields & floor panels
- Tractor, bus & rail interiors
Aerospace & rail
- Seat backs & tray tables
- Overhead bins & luggage compartments
- Interior wall panels
Medical & healthcare
- Diagnostic machine housings
- Mobility aid panels (wheelchairs, beds)
- Sterile equipment covers
- Large enclosures for medical devices
Industrial & machinery
- Equipment guards & safety covers
- CNC & automation housings
- Custom machine panels
- Storage & utility enclosures
Marine & outdoor
- Boat dashboards & hull components
- Kayak & canoe shells
- Protective outdoor panels
- Recreational vehicle components
Consumer & retail
- Appliance housings (fridge, washer, vacuum)
- Furniture panels & chair shells
- Luggage & travel cases
- Fitness equipment components
Thick-gauge parts we form
Large, structural heavy gauge thermoformed components across automotive & EV, aerospace, appliances, medical, signage and industrial — formed on the largest heavy gauge thermoforming bed in India.
EV body panels & bonnets
UV-stable ASA/ABS exterior panels and bonnets — no expensive metal tooling.
Automotive door & trim panels
Textured interior door cards, trims and cladding for vehicles.
Automotive dashboards
Large formed dashboard and console panels with integrated cut-outs.
Aircraft & rail interior panels
FR-grade interior panels and trims for aircraft, bus and rail cabins.
Kiosk & equipment fascias
Self-service kiosk fascias and machine front panels with display cut-outs.
Refrigerator & appliance liners
Deep-drawn HIPS/ABS inner liners and white-goods panels.
Medical device enclosures
Dimensionally stable, ESD-safe housings for medical equipment.
Signage & backer panels
Embossed sign faces and backer panels for retail and fuel-retail branding.
Exhibition & display modules
Formed display panels and modular stands for retail and events.
A sample of thick-gauge work. Send your drawing for a DFM review →
The thick gauge thermoforming process
From material to precision — engineered for strength and quality at every step.
01
STEP 01
Material selection
Choose a thick-gauge sheet (2–12 mm) for strength, impact, UV, FR or chemical durability — ABS, HDPE, HIPS, PC, PMMA, ASA or PP.
Right material for right performance
02
STEP 02
Sheet heating
Heat the thick sheet in infrared or convection ovens until evenly softened, with sag control keeping the sheet uniform.
Uniform heating for consistent forming
03
STEP 03
Clamping & forming
Clamp and form over a large precision mould using vacuum or pressure forming for accurate, repeatable parts.
Accurate forming for the desired shape
04
STEP 04
Cooling & setting
Cool with air or water to lock in rigidity and dimensional stability before the part releases from the tool.
Stable shape with excellent rigidity
05
STEP 05
Trimming & finishing
5-axis CNC trimming for precise edges and cut-outs, plus drilling, painting, printing and assembly.
Clean edges & a premium finish
06
STEP 06
Quality control
Every part inspected for dimensional accuracy, mechanical strength and surface finish — ISO 9001, COA/MTC on request.
Tested. Verified. Trusted.
Let’s build it
Large or structural part to form?
The largest thermoforming bed in India, in-house tooling, FR and UV grades. Send your drawing for a DFM review and quote.
ISO 9001:2015 certified · Most quotes back within 24 hours