Materials for
Heavy-Gauge Thermoforming.
Floe Thermoforming forms heavy-gauge HMWPE, HDPE, ABS (monolithic and COEX), TPO (monolithic, COEX, and FR-grade), and PC/ABS as standard. Additional engineering thermoplastics, including acrylic, polycarbonate, PETG, and Kydex, are formed by program for specific OEM structural, surface, or compliance needs such as UV, impact, chemical, or flame-retardant performance.
Standard heavy-gauge materials
These run every day on the floor. Selection comes down to structure, environment, surface, and compliance.
HMWPE / HDPE
Impact, chemical, and weather resistance for tough utility and structural parts.
ABS Monolithic
The structural workhorse, stiff, dimensionally stable, easy to finish.
ABS COEX
Multi-layer with a surface capstock for UV, scratch, or cosmetic performance.
TPO Monolithic
UV and impact resistance for exterior and weather-exposed parts.
TPO COEX
TPO with a capstock layer for added surface performance.
TPO FR
Flame-retardant grade for transportation interiors (FMVSS 302).
PC/ABS
Toughness with thermal stability for demanding structural-cosmetic parts.
Monolithic vs. COEX sheet
Monolithic sheet is a single homogeneous material through the cross-section. COEX (coextruded) sheet combines layers, typically a structural substrate with a surface capstock, so you can engineer the surface separately from the structure.
Spec COEX when you need UV stability, scratch resistance, or a specific cosmetic surface without changing the base resin doing the structural work.
Standards compliance
When the part lives in a vehicle interior, aircraft, or electronics enclosure, the material has to carry the certification.
Questions OEM engineers ask
What materials are used in heavy-gauge thermoforming?
Floe Thermoforming's standard heavy-gauge thermoforming materials are HMWPE/HDPE, ABS (monolithic and COEX), TPO (monolithic, COEX, and flame-retardant FR), and PC/ABS. Additional engineering thermoplastics, including acrylic, polycarbonate, PETG, and Kydex, are formed by program for specific OEM requirements.
What is COEX sheet and when should I spec it?
COEX (coextruded) sheet is a multi-layer thermoplastic with a substrate layer for structure and a capstock layer for surface performance. Spec COEX when you need UV stability, scratch resistance, or color quality on the visible surface while keeping structural performance in the substrate.
When do I need a flame-retardant (FR) thermoplastic?
Flame-retardant grades are required when the part must meet transportation interior standards, most commonly FMVSS 302 (motor vehicle), FAR 25.853 (aircraft), or UL 94 V-0 (electronics). TPO FR is the most common heavy-gauge FR thermoplastic.
What materials meet FMVSS 302?
FMVSS 302-compliant thermoforming materials commonly used at Floe Thermoforming include TPO FR, ABS formulated to meet UL 94, PVC/Acrylic alloys, and PC/ABS UL-approved grades. Material specification is part of the DFM review for any transportation interior program.
Can I supply my own sheet stock?
Yes. Floe Thermoforming accepts customer-supplied sheet stock when an OEM has a preferred material source. Material qualification and validation are part of the program management process.
What is the difference between monolithic and COEX?
Monolithic sheet is a single, homogeneous material throughout the cross-section. COEX (coextruded) sheet combines two or more material layers, typically a structural substrate with a surface capstock, produced as a single sheet. COEX gives you the structural performance of one material with the surface, UV, or color performance of another.
Send us the part. We'll tell you how to build it.
Upload your drawing or describe the program. NDA-friendly. We review every RFQ ourselves, response within 1 business day.