Custom Thermoforming Car Door Panels

SKU Custom-Thermoforming-CarDoorPanels

Material: ABS
Size: As client requested
Color: Multi-color options
Logo: As client requested
Process: Thick-gauge thermoforming
OEM Service: Yes

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What is the panel under the car door called?

The panel under a car door can have two different names depending on the region:

  • Rocker panel: This is the most common term used in North America. It refers to the stamped metal panel that runs along the bottom of the car, directly below the doors. It provides structural support and protects the underside of the car from debris and moisture.
  • Sill panel: This term is more commonly used in the United Kingdom and some other parts of the world. It refers to the same panel as the rocker panel, but the term “sill” generally refers to the lower edge of an opening, such as a doorway or window.

So, depending on where you are, the panel under the car door can be called either the rocker panel or the sill panel.

What material is used for car door panels?

Car door panels actually use a combination of materials for different parts, each serving a specific purpose:


  • Metal: The core structure of most door panels is made of steel for strength and rigidity. This ensures the panel can withstand impacts and maintain the car’s structural integrity.
  • Aluminum: In some high-end or lightweight vehicles, aluminum might be used for specific parts due to its strength-to-weight ratio.

Interior Trim:

  • Injection-molded plastic: This is the most common material for the main door panel body. It’s typically ABS plastic or thermoplastic olefins (TPO), chosen for their affordability, lightweight nature, and ability to be molded into complex shapes.
  • Composite materials: In some cases, fiberglass or other composites might be used for specific parts like speaker grills or trim pieces, offering a balance of strength and design flexibility.


  • Fabric: A wide variety of fabrics are used, including vinyl, leather, suede, and alcantara. The choice depends on factors like desired aesthetics, durability, budget, and the car’s overall style.
  • Other materials: In some luxury cars, you might find wood veneers, carbon fiber, or even metal accents for a premium feel.

Additional elements:

  • Foam padding: A layer of foam padding is added for soundproofing, comfort, and to give the panel a more sculpted look.
  • Adhesives and fasteners: These are used to securely attach all the different components together.

Important to note:

  • While thermoforming is used for some decorative trim pieces in car door panels, it’s not suitable for the entire structure due to safety concerns regarding strength and impact resistance.
  • The specific materials used can vary depending on the car model, trim level, and year of manufacture.

I hope this clarifies the different materials used in car door panels!

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