Aerospace Thermoforming

Precision Thermoformed Components for the Aerospace Industry

At Reliable Formed Plastics, we have a proven track record of manufacturing high-quality, durable components for Tier 1 Aerospace Suppliers and OEMs. Our expertise in thermoforming top-grade plastic resins offers a cost-effective, lightweight alternative to traditionally metallic aerospace parts — without compromising strength, durability, or performance.

By utilizing advanced thermoplastic materials, we can produce critical aerospace components that meet low-tolerance industry standards while significantly reducing cost and weight. Our precision-formed parts include, but are not limited to:

Interior panels and covers
Instrument bezels and housings
Protective cases and enclosures
Transparencies, such as instrument windows and exterior lenses

We specialize in processing a wide range of high-performance, aerospace-grade materials, including:

ULTEM® (PEI)
Boltaron®
Kydex®
Polycarbonate (Lexan®) / FR Polycarbonate
Nylon
Acrylic
Composite and fiber-reinforced resins

Our facility operates under a rigorous quality management system, holding both AS9100 Rev. D and ISO 9001:2015 certifications, ensuring that every part we manufacture meets the highest standards of precision, safety, and performance. We also offer assembly and sub-assembly services, allowing us to deliver ready-to-use components for streamlined production and integration.

At Reliable Formed Plastics, we are committed to supporting the aerospace industry with superior thermoformed solutions — delivering lightweight, high-strength components that drive efficiency and innovation in aircraft design and manufacturing

LEXAN WINDOW

Pictured to the right is a Lexan window for an instrument panel on a helicopter. Custom molds and trim fixtures were also planned and fabricated for our aerospace customer. The part was created using SolidWorks CAD software and manufactured with the help of Mastercam CAM software. A first article inspection (FAI) was produced from 9034 Lexan (polycarbonate) and sent to the client for approval. Once approved, vacuum thermoforming followed by 5-axis CNC routing were employed to create the instrument panel window.

The window, which was 15.25″ long, 13.67″ wide, .050″ high, and weighed only about 6.5 oz., was machined to exacting tolerances of ±0.010″. Dimensional verification was used during the CNC process and visual quality control was applied during forming. When completed with a smooth clear finish, the parts were marked, packaged to Mil-Specs standards and shipped. We now manufacture at least 500 of these Lexan windows annually to Mil-Spec standards for delivery to the Southeastern U.S.

ULTEM EXHAUST PORT

The red part to the right is an exhaust port made for helicopters. Due to the high temperature requirements for the application, the material used is ULTEM (PEI – Polyehterimide). ULTEM is a high grade plastic coveted for its ability to resist chemicals and high temperatures along with its stable electrical properties over a wide range of frequencies. ULTEM is often leveraged in medical devices and chemical instrumentation due to its solvent and flame resistance. There are also glass filled ULTEM options which we have examples of on the Composite Fabrication page.

COMPOSITE FABRICATION

Reliable Formed Plastics also has the ability to form fiber woven/impregnated materials. These composite materials often serve as excellent Flame, Smoke, and Toxicity deterrents which are highly valued in many aerospace applications. The result in forming such materials is a very high grade, highly durable, yet extremely light weight product. Pictured below Glass ULTEM and Carbon Fiber covers.