Thermoformed Plastics Solutions Blog

Insights into Turnkey Manufacturing of an Engine Cover Assembly

Posted by Jeffrey Geiman on Nov 21, 2014 9:27:00 AM


Recently, we completed a turnkey project for a manufacturer of heavy construction equipment. This particular client came to us in need of 2,000 engine cover assemblies that offered durability, outstanding quality, and affordability. As with all the projects we work on at McClarin, our team envisioned a production and delivery plan that would meet our client’s specific requirements.


To create the engine cover assembly, we chose to utilize two thermoformed panels of natural ABS. Thermoforming is one of our more commonly used molding processes due to its many benefits, which include:

  • High adaptability with various materials
  • Lower tooling costs compared to matched die molding
  • Cost-effective tooling for very large parts

The two panels, which measure approximately 17’ in length and 5’ in width, featured a painted exterior and a metallic copper coated interior. To attain the proper coating, we used a batch booth approach to spray paint the exterior; prior to painting, we made sure to take the critical step of sanding and treating the surface of each ABS panel with an adhesion promoter.

The interior copper coating was added for RF protection purposes. Following the coating and assembly process, the finished assemblies were ready for shipping in returnable packaging.

As with all of our turnkey projects, the engine cover assemblies arrived at the customer’s facility ready to be installed immediately. This important aspect of any turnkey project saves clients significant amounts of labor in assembly and material handling. 

To learn more about this engine cover assembly project, download our new case study:

Turnkey Manufacturing Case Study





For help on any of our other plastic manufacturing projects, please feel free to contact us today.