Thermoformed E-Bike Wheel Cover

The task was to develop a plastic cover matched to the geometry of an existing electric-bicycle wheel.

The finished part needed to suit the specific application in shape, dimensions and opening positions. The product geometry first had to be developed and then adapted to the thermoforming and finishing processes.

From the outset, the project was planned as a custom plastic part, from development of the solution through to the finished production run.

The starting point for the design was the wheel to which the cover needed to fit.

Its dimensions were used to develop the cover diameter, profile and shape, central opening and other characteristic product areas.

The manufacturing technology was also considered during design so that the defined geometry could be produced reliably by thermoforming PS and then finished accurately.

Once the product had been defined, dedicated thermoforming tooling was designed.

The tool shape was adapted to the shallow three-dimensional geometry of the cover, its outer rim and other details formed during the process.

After design, the tool was manufactured and prepared for the first trial parts.

A functional prototype was produced before series manufacturing.

The prototype was used to check the geometry and fit against the relevant wheel and to verify the results of thermoforming and final trimming.

The solution for the production run was approved only after the prototype had been checked.

The product was manufactured from 2 mm polystyrene (PS).

The heated material was thermoformed over the prepared tool so that it took on the designed geometry of the wheel cover.

After forming, final trimming and processing were carried out, including definition of the outer contour and required openings.

This converted the thermoformed blank into a finished plastic part ready for its intended application.

Once the prototype had been approved, a production run of 50 wheel covers was manufactured.

The same tool and defined manufacturing process enabled the geometry to be repeated across the complete run, while every part underwent final trimming and processing after thermoforming.

From product and tooling development through to completion of the ordered production run, the part of the project carried out by TIM Infinity was completed within 15 days.