Thermoformed Plastic Consoles – designed with the client in mind!

Thermoformed Plastic Consoles for Specialty Vehicle Applications

Arrowhead Plastic Engineering specializes in designing and producing high-quality thermoformed plastic consoles for a wide range of specialty vehicle applications. Since our founding in 1972, we’ve been supplying custom thermoformed parts to industries including heavy trucks, buses, and accessibility-enhanced vehicles. These industries typically operate with smaller production volumes compared to mainstream automotive manufacturing, which makes thermoforming the most cost-effective and flexible production method.

Unlike injection molding, which often requires costly tooling that can’t be justified at lower volumes, thermoforming allows for faster design changes and lower production investment. For more details on the differences between molding methods, visit this comparison, and explore our unique Eco-Tooling solution for thermoforming that reduces upfront costs for many of our customers.

The featured thermoformed plastic console was developed through close collaboration with the customer to meet the interior needs of converted, handicap-accessible vehicles. The customer removes most factory elements and replaces them with customized solutions, including decorative thermoformed panels to conceal wiring and components associated with their modifications. This console blends form and function, providing an aesthetic finish while also addressing ergonomic and storage needs inside the vehicle.

Thermoforming was the ideal solution to quickly prototype, modify, and produce this part without incurring the massive costs of traditional molding methods. Injection molding would have required multiple prototype tools and expensive hardened tooling—driving costs into the hundreds of thousands. Instead, this thermoformed design allows for flexibility in height and base contour to adapt to different vehicle platforms. The console is made from low-gloss black ABS plastic with a Seville texture and includes a vinyl-wrapped armrest (covered in Naugahyde), along with two drop-down cup holders for rear-seat passengers. It measures 34″ x 11″ x 18″, and other textures or colors can be produced with sufficient order volumes.

Although originally developed for a specific client, Arrowhead retains ownership of the tooling and is able to manufacture this thermoformed plastic console for new customers as well. We can also customize the design to suit your specific use case, whether that involves vehicle integration, storage requirements, or branding needs.

Our team takes great pride in helping customers transform their ideas into functional, manufacturable products. Whether you’re looking to purchase this console or collaborate with us to design your own, we’re here to support your goals. Contact us here to get started.