How thermoforming delivered cost-effective reach truck parts

Cost-effective body panels for material handling equipment are often produced using thermoforming processes. And CNC trimming can multiply the savings. Profile’s work on a reach truck project for a material handling OEM demonstrates the value.

Project background

Reach trucks are forklifts designed to navigate high racks and narrow aisles in distribution centers with high-density storage. Since these vehicles are often electric-powered, energy efficiency is essential for end user customers. 

An existing OEM customer was developing a new reach truck that would be offered in several different versions. They asked Profile to thermoform multiple parts for the cockpit cover, along with other components. 

Challenges

The key challenge in the cockpit cover project was finding how to keep tooling costs low. The OEM wanted to create a common cover system for the top of the dashboard. The front part of the dash needed 4 different versions to accommodate several different truck models that offered different size battery modules. 

The middle and rear dash components would stay consistent across models. 

Material handling applications require rugged parts. Many components continue to be stamped from steel, but thermoforming is becoming more common. The dash components needed to be thick and rigid, and they needed to have UL94 V-0 flame rating.

Cost-effective design solution

Profile engineers worked closely with the OEM’s design team. They developed a large front cover part that could be made on a single pressure forming tool and then trimmed to 4 different specific sizes. While the 40” length stayed the same, the part could be trimmed to a 20.8” width or down to a 13.8” width.

 

Fixtures to hold complex parts steady are crucial for successful, repeatable trimming. Trim fixtures are often made of composite materials, much less expensive than the machined aluminum used for pressure forming molds. 

One trim fixture worked for all four versions of the front cover. Only the programming changed, saving additional costs.

Profile was one of the first thermoformers to implement 5-axis CNC trimming in the 1970s. 

The material world

Material expertise also plays a part in successful part development. Profile has a great deal of experience working with the KYDEX® T brand (PVC/Acrylic blend) thermoplastic used for this project. 

The impact and chemical resistance of the material, plus its flame rating, were important for the application. It’s also very workable for thermoforming, providing good surface aesthetics for in-mold texturing. While other components featured custom color, the dash parts were black.

Because of the complex shapes, some sections featured deep draw. The application also required the parts to be thick. Profile started with a 0.25” gauge plastic sheet to ensure that no features of the finished parts ended up less than 0.125”. 

Success results in long project life

While some models of the reach truck sold more than others, the common cover system helped save tooling and component costs. Profile pressure formed up to 2,000 of each piece per year over an 11 year life cycle for this product line.