Arrowhead Plastic Engineering partnered with a specialty vehicle manufacturer to design and produce custom thermoformed plastic consoles for handicap-accessible vehicles. This customer needed a solution that could integrate seamlessly into modified vehicle interiors, offering both decorative appeal and functional storage space.

The project began with a close collaboration between Arrowhead’s engineering team and the customer’s design staff. Working together, we developed a thermoformed plastic console that blended form and function, covering exposed wiring and auxiliary components created during the vehicle conversion process. Thermoforming proved to be the ideal manufacturing method for this application, offering cost-effective prototyping, rapid design modifications, and lower tooling investment compared to traditional injection molding.

 

Arrowhead thermoformed the consoles from low-gloss black ABS plastic with a Seville texture, providing a clean, professional look and excellent durability. To enhance comfort and usability, the consoles were finished with a vinyl-wrapped Naugahyde armrest and included integrated drop-down cup holders for rear-seat passengers. Each console measures 34″ x 11″ x 18″, with options for additional colors and textures available based on order volume requirements.

Unlike injection molding, which would have required extensive investment in multiple prototype and production tools, thermoforming allowed for flexible changes to the overall height and base contour of the console. This versatility made it easier to adapt the design for different vehicle models without excessive cost or delay.

Arrowhead retains the production rights and tooling for this particular thermoformed plastic console and can customize or adapt the design for new customers and applications. Whether you need a console for a specialty vehicle, commercial fleet, or unique interior program, our team is ready to help transform your ideas into durable, production-ready parts.

Interested in learning more about Arrowhead’s capabilities for custom thermoformed plastic consoles? Contact us to start the conversation.