Thermoformed Robot Housings
Your robot changes every generation.Its housing tool doesn't have to.
Thermoformed Robot Housings are shaped from heated plastic sheet. FUNYO forms single parts up to 2600 × 1600 × 600 mm from sheet up to 15 mm; housings commonly use 8–10 mm. Forming tools take about 1–3 weeks and cost under 1/10 of a comparable injection mold.
- Max. part size
- 2600×1600×600mmL × W × H, formed in one piece
- Max. sheet thickness
- 15mm8–10 mm is typical for housings
- Tooling lead time
- 1–3weeksvs. about 6–10 weeks for a comparable injection mold
- Tooling cost
- <1/10of a comparable injection mold
- 01Fast iterations
- New openings: new program, same tool
- 02Big bodies
- One piece up to 2.6 m
- 03Easy service
- Covers split along the service path
Thermoformed parts for robotics & autonomous equipment
From the main body shell
to a battery-hatch cover.
Robot parts that suit heavy-gauge thermoforming:
- AMR and logistics
- Cleaning robots
- Delivery and service robots
- Inspection robots
- 01
Body shell and top cover
Large curved shells in one piece; for front/rear or upper/lower splits, parting lines and datums are fixed before tooling.
- 02
Sensor fascia and front face
Openings follow the field of view of lidar, cameras and ultrasonic sensors; edges are CNC-finished.
- 03
Service and battery-access covers
Split along the battery-swap and service path, with quick-release fasteners or hinges.
- 04
Chassis shrouds and side skirts
Cover the chassis and drive; load bearing and bump protection stay with the robot's structure.
Examples of thermoformed components
Examples:
formed parts you can see.
Formed parts from the FUNYO company profile, picked for this industry. Need something similar? Send a drawing or a photo.
Send drawings, answer in 2 working days
AI and service robots 
Warehouse robot cover 
Drone shell 
ReferenceService robot shell (hotel delivery robot)
Images from the FUNYO company profile. Some show the complete product; the formed part is the one named in the caption. Photos labelled “Reference” show similar products to explain component forms; they are not FUNYO delivery cases.
Thermoforming compared with other processes
Prototype, pilot, production:
the numbers work at every stage.
Which housing route fits depends on where the robot program is:
Send drawings, answer in 2 working days| Program stage | Heavy-gauge thermoforming | Injection molding |
|---|---|---|
| Prototype and pilot (tens of units) | Tooling in about 1–3 weeks at low cost | A mold rarely pays; usually machined or printed parts |
| Design revisions | Opening changes: edit the CNC program; shape changes: modify the forming tool | Mold changes are costly and slow |
| Steady production (hundreds to thousands) | Ongoing supply; around 3,000 parts a year can apply for a no-tooling-charge evaluation | Depends on shape and volume |
| High volume (10,000+) | We can keep supplying, but piece price is usually above molding | Lower piece price; time to move to a mold |
General comparison; we confirm against your drawing, material and volumes.
Assembly, access and interface design
Swap the battery
without stripping the robot.
How the housing splits decides how much comes off for service. We settle three things:
Battery swap and service path
First where the battery comes out, which covers open and what stays put; then the cover boundaries and fixing points.
Needed: overall layout and battery-swap direction
Sensor field of view
Give us the field of view and mounting positions of lidar, cameras and ultrasonic sensors; openings and edges are machined to them.
Needed: sensor models and fields of view
Design iterations
If a new version only adds a port, we change the CNC program and fixtures; only a change to the platform size means a new forming tool.
Needed: a change list between versions
Sheet materials and project requirements
Indoors, wet-cleaned, sun-baked:
different materials.
8–10 mm sheet is typical, up to 15 mm. By use:
Heavy-gauge thermoforming| Indoor delivery and service | ABS: stiff and easy to machine; color matched to swatches. |
|---|---|
| Wet cleaning | Tell us the cleaner and washdown method; for chemical contact choose PP, PE, or ABS verified by wipe tests. |
| Outdoor inspection | A weatherable grade or surface treatment, sourced per project and checked on samples. |
| Sensor windows | Clear PC or PETG; optical and RF transmission verified on samples against the sensor's requirements. |
Exact grade, color and texture are approved on physical swatches and samples.
Factory, CNC trimming and inspection
Forming, trimming, inspection:one plant in Zhuhai.
FUNYO started in precision machining in 2004 and has been thermoforming since 2013. Heavy-gauge forming, CNC trimming and dimensional inspection all happen in our Doumen plant, and we machine our own forming tools, so revisions don't wait on outside shops.
Facts you can check
- 2004
- Founded; 20+ years of precision machining
- 2005
- Became a tier-1 supplier to Gree
- ISO 9001 · 14001
- Quality and environmental management certified
- 2024
- Recognized as a High-Tech Enterprise
- ABS · PET/PS
- Own plant for thermoforming sheet
- 4 hours
- Response to design requests
Selected long-term customers
These relationships cover precision formed trays, CNC parts and other work. Listed in no particular order.
Lead time from drawing to delivery
From drawing to production,
and how long each step takes.
Typical timings. Complex parts or special materials get a specific schedule when we quote.
- Within 4 hours
Response
An engineer contacts you to confirm use, size and quantities.
- 2 working days
Evaluation and quote
We tell you whether heavy-gauge fits and quote it side by side with injection molding.
- About 1–3 weeks
Tooling
After design review we machine the forming tool in-house.
- By complexity
Samples
Formed, trimmed and drilled, then fitted to your frame or mating parts.
- Per order
Production
Checked against the approved sample for size and finish, then packed and shipped.
Thermoforming for robotics & autonomous equipment: FAQ
Bring the robot layout.
We'll work out the housing.
CAD, a frame drawing or a concept layout all work. Tell us about sensors, service access and expected annual volume.
FAQ
Can thermoforming be evaluated for robotics & autonomous equipment at 300–3,000 units per year?
300–3,000 units is a quoting scenario, not a break-even threshold. Compare part size, assembly, material, tooling and unit costs before selecting a process.
What size and sheet thickness are available for robotics & autonomous equipment?
The maximum single part is 2600 × 1600 × 600 mm, with sheet up to 15 mm. Housings commonly use 8–10 mm sheet. Finished dimensions depend on geometry and trimming allowance.
Which sheet grades should I specify for robotics & autonomous equipment?
ABS, PC, PVC, PETG and PP can be formed. PC or PETG can be evaluated for transparent parts. PE, weatherable, flame-retardant and antistatic grades are sourced and sampled for the project.
How long does tooling for robotics & autonomous equipment take?
Forming tooling costs under 1/10 of a comparable injection mold and takes about 1–3 weeks. Comparable injection molds take about 6–10 weeks. Confirm the scope against the drawing and material.
What should I send for a 2-working-day thermoforming assessment for robotics & autonomous equipment?
Send drawings or photos, dimensions, annual and first-order quantities, assembly interfaces and operating conditions. We respond in 4 hours and provide the applicability assessment and comparison quote in 2 working days.
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