Case Study: HVAC Ductwork for a Custom Cab Manufacturer Equipment

This customer was a cab manufacturer supplying cabs to some of the top OEMs in the world in agriculture, construction, forestry, military, mining, rail, and specialty truck markets.

The Challenge

The cab manufacturer came to ICP to determine the feasibility of manufacturing HVAC ducting for a cab to ensure the cab was comfortable in varying temperatures for the operator by providing consistent airflow.

This customer had looked into other plastic processes but unfortunately, the tooling was cost-prohibitive from moving the project forward based on the volume and life cycle of the product.   

The overall goals for this project were:

• HVAC ducting that would ensure a comfortable cab for the operator
• A solution that was cost-effective

Our Solution

ICP made the recommendation to take two thermoformed pieces and bond them together to create the ductwork.

1. Inner-piece – Utility black ABS to save on cost while using a material that is easy to bond to. 
2. Exterior visible surface – Custom gray ABS to match the rest of the interior plastic pieces in the cab creating an aesthetically pleasing atmosphere.. 

The two parts were formed and trimmed with different molds and then bonded together using a slurry made from ABS chips and solvent creating an air-tight seal.   

The end result was a solution that met both objectives: comfort for the operator, but cost-conscious. The project moved forward with production and was a success for both parties.  This same concept was used on additional projects helping the customer achieve their goals while keeping budget in mind.