Why Is Shipping So Expensive for Tanning Bed Acrylics? The Complete Guide

If you’re ordering a replacement tanning bed acrylic—whether for a commercial tanning salon or a home tanning unit—you’ve probably noticed that shipping costs can seem higher than expected. At SunalParts.com, where we manufacture acrylics for all makes and models of tanning beds, this is the #1 question customers ask.

Below, we break down exactly why tanning bed acrylic shipping costs what it does—and how you can avoid surprises when placing an order.

1. Tanning Bed Acrylics Must Meet UPS & FedEx Size Limits

A tanning bed acrylic requires careful packaging, which makes the box long, wide, and bulky. FedEx and UPS have strict size limits:

Length + Girth cannot exceed 165 inches.

If the package exceeds this limit, FedEx and UPS will not accept it, and the acrylic must ship via a freight trucking company.

Acrylic Box

Acrylic Box

2. If the Box Is Oversized, It Must Ship Freight

Once the package exceeds FedEx/UPS dimensional limits, it must travel by LTL freight, where pricing varies by:

  • Destination ZIP code
  • Residential vs. business address
  • Accessorial fees (common in the freight industry)

Typical freight surcharges include:

  • Residential delivery: $50–$85
  • Inside delivery: $40–$75
  • Appointment delivery: $20–$35

These fees are standard industry-wide and mandatory when required based on the destination.

3. Even FedEx Ground Pricing Is Based on Dimensional Weight

If your acrylic fits within the 165″ limit, it ships FedEx Ground. At SunalParts.com, we offer heavily discounted FedEx rates, but customers are often surprised by how FedEx calculates cost.

FedEx uses dimensional weight, not actual weight.

Example shipment:

  • Box size: 76″ × 33″ × 6″
  • Actual weight: 30 lbs

FedEx.com published retail rate for this package: $471.50 (depending on ZIP code)

We rarely charge anywhere near that amount because we pass our discounted rates directly to customers.

Bonus tip: You can ship up to three acrylics for the same price as one because adding more acrylics does not significantly change the box size.

4. Always Inspect the Acrylic at Delivery

Whether shipped FedEx or freight, follow this rule carefully:

Do NOT sign the delivery paperwork until you open the box and inspect the acrylic.

If the acrylic is damaged:

Refuse the shipment.

This allows the carrier to return it at no cost and ensures we can remake and reship your acrylic quickly.

Fedex Signature

Fedex Signature

5. Always Measure Your Old Acrylic Before Ordering

Never rely on model names or numbers alone. Even within the same tanning bed model, acrylic sizes can vary due to:

  • Different production years
  • Manufacturer revisions
  • Aftermarket part substitutions
  • Bench/canopy design changes

You should always measure your old acrylic after removing it from the bed.

Click here to watch our video on how to properly measure your tanning bed acrylic.

Final Thoughts

Shipping tanning bed acrylics is uniquely expensive because of strict size limits, dimensional weight, and freight surcharges. Every carrier—FedEx, UPS, and all trucking companies—bases pricing on these same rules.

At SunalParts.com, we work hard to keep shipping as affordable as possible by offering:

  • Discounted FedEx rates
  • Efficient packaging that stays within size limits
  • Bundled shipping (up to 3 acrylics for one price)

If you have questions about sizing, shipping, or ordering, we’re here to help.