How we helped a leading HVAC equipment manufacturer replace imported Kydex with locally sourced ABS FR V0 — maintaining flame-retardant compliance while reducing costs by 15% per unit through a smart mixed-material strategy.
15%
Cost Reduction Per Unit
100%
Flame Retardant
Zero
Import Dependency
40%
Weight Savings vs Metal
Project Overview
A leading manufacturer of commercial HVAC equipment approached Formpack with a requirement for thermoformed plastic hoods and main covers for their air conditioning product line.
Client
A leading HVAC equipment manufacturer
Requirement
ABS Plastic Hoods and Main Covers for commercial air conditioning units
Part Dimensions
Up to 1375 × 616 mm
Original Material Spec
Imported Kydex (thermoplastic acrylic-PVC alloy)
Core Challenge
High cost of imported Kydex material while maintaining flame-retardant compliance
Final Outcome
15% cost reduction per unit through smart material substitution strategy
The Challenge
The project required balancing cost reduction with uncompromising safety standards — a challenge that demanded deep material science expertise.
The client's original specification called for imported Kydex — a premium thermoplastic acrylic-PVC alloy. Import duties, shipping, and exchange rate fluctuations made the material cost unpredictable and expensive.
All covers required flame-retardant compliance. Any material substitution had to maintain this critical safety standard without compromise.
The project involved multiple hood and cover variants with different geometries, each requiring its own tooling. Significant tooling investment meant the material choice had to be right from the start.
The client needed pricing that was competitive with their existing sheet metal covers while delivering the weight savings and corrosion resistance benefits of plastic.
Our Solution
Rather than simply quoting the specified material, we took a consultative approach — analyzing the application requirements and proposing a smarter, more cost-effective solution.
We conducted a detailed technical comparison between imported Kydex and locally sourced ABS FR V0. The analysis covered mechanical properties, flame retardancy ratings, UV resistance, chemical compatibility, and forming characteristics.
Rather than a blanket material substitution, we proposed a smart mixed-material approach: ABS FR V0 for safety-critical components requiring flame-retardant compliance, and standard ABS for non-critical covers where flame retardancy was not mandated.
We provided a fully transparent cost breakdown — raw material, conversion costs, CNC trimming, inspection, packaging, overheads, and profit margins — allowing the client to see exactly where savings were achieved.
All flame-retardant components were tested and validated against stringent fire safety requirements. Third-party test reports were provided for each material grade used in the final production parts.
CNC-machined aluminum molds were designed and manufactured in-house. First article samples were produced, dimensionally inspected, and submitted for client approval.
Material Comparison
The core of our value engineering approach was a transparent, data-driven comparison between the specified imported material and the locally sourced alternative.
| Property | Imported Kydex | Local ABS FR V0 | Verdict |
|---|---|---|---|
| Flame Retardancy | V0 Rated | V0 Rated | Equal |
| Material Cost | High (imported) | 30-40% lower (local) | ABS FR V0 wins |
| Supply Chain Risk | Import dependent | Extruded in-house | ABS FR V0 wins |
| Lead Time | 8-12 weeks (import) | 1-2 weeks (in-house) | ABS FR V0 wins |
| Impact Resistance | Good | Excellent | ABS FR V0 wins |
| Forming Characteristics | Excellent | Very Good | Comparable |
| Surface Finish | Excellent | Very Good | Comparable |
| Chemical Resistance | Excellent | Good | Kydex edge |
Results
15%
Cost Reduction Per Unit
Achieved through local ABS FR V0 sourcing and mixed-material strategy
100%
Flame Retardant
All safety-critical parts meet stringent flame-retardant requirements
Zero
Import Dependency
Eliminated reliance on imported Kydex — all materials sourced and extruded locally
40%
Weight Savings vs Metal
Thermoformed ABS covers are 40% lighter than the original sheet metal panels
Local ABS FR V0 can replace imported Kydex for many HVAC applications while maintaining flame-retardant compliance
A mixed-material strategy — using FR grades only where mandated — delivers significant cost savings without compromising safety
Transparent cost engineering builds trust and positions the thermoformer as a value engineering partner
In-house sheet extrusion enables complete material control and eliminates import supply chain risks
Dimensional inspection ensures first-article quality matches the original specification
Send us your current part specification — whether it's sheet metal, FRP, or an expensive imported plastic. We'll provide a free technical comparison with thermoforming alternatives, including material recommendations, cost analysis, and compliance verification.