The Camera Cover for Sports Live Events

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⌈Case Study⌋ ⌈Thermoforming⌉ ⌈Acrylic Sheets⌉

We are excited to share our latest project: A specially designed camera cover aimed at protecting cameras during live sports events. As the demand for high-quality live sports coverage grows, so does the need for reliable enclosure protector that can withstand the rigors of the environment.

What are the main focuses of the project?

The primary purpose of the camera cover is to provide protection for cameras used in live sports broadcasting. During camera housing, they are often exposed to unpredictable environments where they can be subject to impacts, falls, or other physical hazards. The cover is designed to shield the camera from such risks.
In live sports coverage, maintaining high image quality is essential. The camera cover aims to protect the equipment without compromising optical clarity.

Excelite Team provided various options from materials to thermoforming types, and after considering them all, the customer choose the optical acrylic sheets and vacuum thermoforming method.

Excelite optical acrylic sheets offered a glass-like, transparent appearance, without any color grounding. Acrylic can be easily thermoformed into complex shapes. This flexibility allows for the creation of custom designs for various products, from automotive parts to decorative items.

Key points in this project included:

1. Material of this cover enclosure:
Initially, the customer considered both polycarbonate and acrylic as potential materials for their project. While polycarbonate is known for its excellent impact resistance, but they finally opted for acrylic.

The primary reason is that acrylic features no color grounding, making it an ideal option for camera housing where clarity and visual appeal are essential. Additionally, acrylic is highly amenable to thermoforming, allowing for the creation of complex structures with ease.

Finally, another significant advantage of acrylic is its low-maintenance requirements; it is easy to clean and maintain, ensuring long-lasting aesthetic quality and functionality.

2. Pressure Thermoforming or Vacuum Forming

Thermoforming is a manufacturing process where a sheet of plastic is heated to become pliable, then shaped or contoured using a mold, and trimmed to create a final part or product. Vacuum forming and pressure forming are two of the most popular types of thermoforming processes.
Vacuum forming is ideal for parts that only need to be precisely formed on one side.

There are two basic types of molds—male and female for pressure forming. With male molds, the sheet of plastic is placed over the mold to contour the inside dimensions of the plastic part. With female molds, the thermoplastic sheet is placed inside the mold to form the outer dimensions of the part precisely.
Both vacuum forming and pressure thermoforming can create the shape. The main difference is in the way how they reduce material stretching and maintain visual quality when forming shapes with deeply curves.

3. Trim Machining

After thermoforming, the sheets need to be trimmed, increasing the complexity of the process.

Acrylic material can’t be trimmed with manual knives or metal die cutting. They will be broken.

A 5-axis CNC router is a sophisticated machining tool that operates along five different axes simultaneously. This type of CNC (Computer Numerical Control) router increases the flexibility and precision of the machining process, allowing for the creation of complex parts and shapes.

4. Polish

After we received a shape, we need to do edge polishing for the camera cover.
Edge polishing is a process used to smooth the edges of materials, enhancing both the look and safety of your finished product.

5. Package

We use wooden cases, paper, bubble wrap and other protective materials to safeguard the cargo during the delivery.

6. Clean and Maintain

Cleaning an acrylic shield requires a gentle approach to avoid scratching or damaging the surface. Here’s a step-by-step guide on how to properly clean an acrylic shield:

Materials Needed

Microfiber Cloths: These are soft and non-abrasive.
Mild Dish Soap: Avoid harsh chemicals that can damage the acrylic.
Water: For mixing with the soap and rinsing.
Optional: Commercial acrylic cleaner (if available).
Spray Bottle: For applying cleaning solution (optional).

The customer expressed their satisfaction with the project, as it not only brought more safety enclosure into their camera live sports broadcast but also blocked harmful UV rays, and improved image quality.