This thermoformed door panel was manufactured using a combination of ABS and flexible vinyl (Naugahyde), offering a high-quality solution for interior applications where both structural performance and surface aesthetics are important. Due to the customer’s low-volume production needs, Arrowhead produced these panels using a cost-effective composite tool, which allowed for quicker turnaround and reduced tooling investment.

ABS was selected as the base material for this thermoformed door panel because of its excellent availability, ease of thermoforming, strong structural properties, and compatibility with adhesives used in the vinyl wrapping process. Its durability and versatility make it an ideal substrate for components that must maintain a solid core while supporting a softer, more tactile surface finish.

To manufacture the panel, Arrowhead first thermoformed the ABS sheet into the required shape, creating a rigid, dimensionally stable core. The formed ABS part was then prepped for wrapping. Simultaneously, a sheet of flexible Naugahyde vinyl was heated in an oven to the optimal forming temperature. Once heated, the vinyl was carefully vacuum-formed over the ABS core, allowing it to conform tightly to the part’s contours. The excess vinyl was then trimmed and wrapped around the edges to create a clean, professional finish.

Companies looking to replicate the look and feel of high-end automotive interiors often choose this approach. A thermoformed door panel wrapped in vinyl offers a soft-touch surface, reduced gloss, and a refined appearance not easily achievable with rigid thermoplastics alone. This combination is ideal for applications in specialty vehicles, commercial interiors, or any environment where tactile comfort and aesthetic appeal are key.

Have a part that might benefit from vinyl wrapping over a thermoformed core?
Contact us today to discuss how Arrowhead can support your project.