Vacuum Formed Protection

Avon Group’s reusable PE Foam protection has found a niche in Car manufacture, protecting a vehicle’s exterior and interior throughout its build or shipping. Many other industries also benefit from these protective products.

Wheel protection

After several years of product development, Avon Group has engineered a solution for Wheel protection which protects the rim and brake shoes with a quick release design.

Interior trim

Interior trim protection products are also available to help avoid damage to interior trim & upholstery whilst in the production process.

Rigid protection

If a vehicle needs protecting during manufacture or shipping, Avon Group can provide a solution. Our bespoke, Vacuum Formed car protection range consists of PE Foam laminated to a rigid polyolefin sheet. The parts are Vacuum Formed and then trimmed to size. This provides a soft Foam inner that is in contact with the vehicle and a rigid outer skin that completely protects that area of the vehicle, be it an internal or external area.

The parts fit precisely onto the vehicle and are held in place using a variety of techniques. These parts are reusable. We not only supply Vacuum Formed protection, but complement this with other products we manufacture, such as Die-cut and extruded Foam products and Tapes.

We are the UK’s leading manufacturer of vacuum formed car body protection systems

Martin Jarvis: Sales Director


Vacuum Forming is a very adaptable technology, allowing both flexible and rigid mouldings in a number of materials. Vacuum Forming in many applications offers a significantly lower cost alternative to Injection moulded and Pressed components. This results from lower tooling costs, especially during the development phase of any project where components are likely to require engineering modifications.

Non-vehicle uses

As well as vehicle use, our protection products are also suited to transit packaging for fragile components.


  • Lower equipment costs (in comparison to Injection moulding)
  • Shorter possible lead-times from concept through to production
  • Lower tooling costs compared to many other Plastic manufacturing techniques
  • Families of parts can be accommodated cost effectively on one tool


  • Less costly design changes, due to lower tooling modification costs
  • The ability to manufacture parts with thinner wall sections
  • The ability to manufacture flexible Foam components easily
  • The component profile can be easily modified to accommodate several trim variations