Thermoformed HDPE Plenum for the Automotive Industry

A client in the automotive industry came to us for a thermoformed component that would be used in the production of an electric vehicle. This thermoformed plastic plenum was used to cool the vehicle’s batteries while the vehicle is being operated. Following the customer-supplied prints, we created the plenum by thermoforming HDPE to the specifications using our single station thermoformer. After thermoforming, we completed the part with CNC trimming, sonic welding, assembly and deburring. The production run for this plastic plenum thermoforming project was 250 units and was completed in 4-6 weeks. We met IMDS and level 3 PPAP standards and worked with check fixtures to adhere to required tolerances.

Northern Plastics is an industry leader with clients in a variety of industries. We work with our clients to turn their ideas into viable products. To learn more about this project, see the table below for the specifications of this thermoformed plastic plenum. Please feel free to contact us with additional inquiries.

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PRECISION THERMOFORMED HDPE PLENUM - PROJECT DETAILS

Applied/Processes

Primary: Thermoforming
Secondary: CNC Trim
Sonic Welding
Assembly
Debur
Pack
Equipment Used to Manufacture PartSingle Station Thermoformer
5 Axis CNC Router
Sonic Welder
Check Fixture
Overall Part Dimensions37″ x 9.6″ x 3″
Material UsedHDPEMaterial FinishHaircellIn process testing/inspection performedCheck Fixture
Visual Inspection
Industry for UseAutomotive IndustryVolumeProduction Run
250 units
Delivery/Turnaround Time4 – 6 weeks
Delivery LocationUSAStandards MetCustomer supplied prints
ISO 9001:2008
IMDS
PPAP 3
Product NamePlenum