September 28, 2026 • 5 min read
Data center plastic fabrication at Blue Ridge Thermoforming (BRT USA) is two processes under one roof in Greenville, SC. CNC-routed HDPE duct bank spacers are one line. Heavy-gauge thermoformed covers, housings, trays, and panels are a separate line. Choosing the right process early avoids the common confusion that every plastic part for a data center is “thermoformed.”
Need: Hole arrays that hold conduits in a concrete bank. Typical parts: Duct bank / conduit spacers
Need: Formed 3D covers, shrouds, housings, trays, panels. Typical parts: Equipment covers, cabinet skins, cable organizers, large panels
Duct bank spacers are not thermoformed. Thickness for spacers is typically 3/8 in or 1/2 in HDPE, cut from your drawing. Thermoformed parts use a forming envelope up to 60 × 100 in and heavy-gauge material from about 0.030-0.500 in, depending on the application.
Choose CNC sheet fabrication when the part is essentially a flat board with a precise hole pattern:
Hole OD, rows × columns, and center-to-center spacing follow the print. Boards ship to the jobsite, including staged deliveries. See custom HDPE duct bank spacers and data center duct bank spacers.
Choose heavy-gauge thermoforming when the part needs formed depth, cosmetics, or enclosure geometry:
Materials available for heavy-gauge work include HDPE, HMWPE, ABS, HIPS, PET/PETG, polycarbonate, PVC, and LDPE (as listed on the data-center plastic parts page). Forming is followed by CNC trimming so openings and edges match the design. Explore equipment covers and kiosks and the hub at custom plastic parts for data centers.
Heavy-gauge forming areas go up to 60 × 100 in. CNC trim and sheet routing both run on in-house 5-axis equipment. Tooling, forming, trimming, and assembly sit under one roof at 184 Commerce Center, Greenville, SC 29615. ISO 9001:2015 applies to the quality system. The same quote path covers either process: tell us whether you need CNC spacers, thermoformed covers and housings, or both.
On the RFQ or drawing package, label the part family clearly:
If a package mixes both (common on campus builds: spacers for duct banks plus covers for gear), send both drawing sets. BRT will quote them as separate lines rather than forcing one process onto both.
CNC HDPE sheet (spacers): underground concrete-encased duct banks; custom conduit arrays; mixed-size power and fiber banks; prefabricated arrays assembled outside the trench; boards that remain in the pour. Typical thickness 3/8 in or 1/2 in. Spacing along the run typically every 4-7 ft.
Heavy-gauge thermoforming (covers and related): equipment covers and shrouds; housings and kiosk-style enclosures; trays and cable organizers; large panels and cabinet skins. Forming envelope up to 60 × 100 in. Materials include HDPE, HMWPE, ABS, HIPS, PET/PETG, polycarbonate, PVC, and LDPE as listed on the hub page.
No. They are CNC-routed HDPE sheet. Thermoforming is used for covers, housings, trays, and panels.
Up to 60 × 100 in, with heavy gauge typically in the 0.030-0.500 in range depending on the part.
Yes. Both process lines run in the Greenville plant. Use the same quote form and specify which line each part belongs to.
Tell us whether you need CNC HDPE duct bank spacers, heavy-gauge thermoformed covers and housings, or both. The quote form is the same path either way.
Custom plastic parts for data centers · Duct bank spacers · Equipment covers and kiosks