Lower energy consumption

Body panels, undertrays, interior mouldings, covers, glazing and housings

Lower mass reduces the energy needed to move the vehicle. In an EV it can improve range or allow a smaller, cheaper battery for the same range.

Protection of electrical systems

Insulation, barriers, cable supports, electronics covers and non-conductive enclosures

EVs introduce high-voltage batteries, inverters, motors and charging systems that must be isolated and protected.

Battery protection

Cell supports, barriers, covers and specialist composite housings

These parts may need impact resistance, electrical insulation, fire performance, heat management and resistance to electrolyte.

Aerodynamics

Smooth undertrays, wheel-area components, fairings and external panels

Moulded plastics can create complex, lightweight surfaces that manage airflow and protect underbody systems.

Thermal and airflow management

Cooling ducts, fan housings, shrouds and air channels

EV batteries and power electronics must remain within controlled temperature ranges.

Sensor integration

Bumper areas, radomes, camera and LiDAR housings, sensor covers and mounting structures

In an automated vehicle, the exterior panel can affect the equipment operating behind it. Material, thickness, paint and geometry become functional decisions.

Passenger environment

Screens, glazing, interior panels, display surrounds, consoles and protective covers

Automated passenger vehicles can require different layouts, interfaces and visibility than conventional vehicles.

Rapid development

Prototype panels, housings, test components and small production batches

New EV and AV developers often need repeated design changes before committing to expensive mass-production tooling.

Design, CAD and material selection

Developing parts from drawings, samples or early concepts

Improves manufacturability before tooling; can reduce material use, operations and unit cost.

Heavy-gauge vacuum forming

Covers, housings, undertrays, interior mouldings, external panels, shrouds and protective enclosures

Comparatively economical tooling, fast development and suitability for prototypes through to repeat batches.

Drape moulding

Curved glazing, screens and transparent panels

Particularly relevant to specialist vehicles, pods and low-volume designs requiring large curved transparent components.

Three-, four- and five-axis plastic machining

Panels, brackets, housings, profiles, holes, slots and final trimming of formed parts

Accuracy, repeatability and complex multi-sided machining, including one-offs and short runs.

Plastic laser cutting

Acrylic and sheet-plastic panels, windows, covers and interface panels

Fast, repeatable production of detailed flat components.

Fabrication, bonding and assembly

Multi-part enclosures, completed panels and fitted assemblies

Reduces the number of suppliers and handovers an OEM or developer must manage.

In-house finishing, warehousing and distribution

Finished repeat-production parts and scheduled call-offs

Better control over quality, lead times and just-in-time supply.