Radomes, interior cabin panels, ducting, fairings, and ground support equipment — thermoformed from flame-retardant ABS, PETG, PC/ABS, and Kydex with full material traceability. From pellet to flight-ready part under one roof.
4m+
Max Forming Length
FR V-0
Flame Retardant Grades
3-4 wk
Mold Lead Time
5
Continents Served
Why Thermoforming for Aerospace
Aerospace demands lightweight, flame-retardant, precision-formed components at volumes where composite layup is too slow and injection molding tooling is unjustifiable. Thermoforming bridges the gap.
Thermoformed plastic panels are 40-60% lighter than equivalent sheet metal or fiberglass parts. In aerospace, every kilogram saved translates directly to fuel efficiency, payload capacity, and operational range.
CNC-machined aluminum molds cost a fraction of matched-metal stamping dies or composite layup tooling. Critical for aerospace programs with 50-2,000 unit production runs where injection molding ROI is unachievable.
ABS FR V-0, PC/ABS, and Kydex grades meet FAR 25.853, UL 94 V-0, and other aerospace flammability standards. Self-extinguishing materials with low smoke and toxicity ratings for cabin-rated applications.
Form parts exceeding 4 metres in a single shot — critical for full-length cabin sidewall panels, cargo bay liners, and large radome covers that exceed the platen limits of injection molding machines.
New mold in 3-4 weeks vs 12-20 weeks for composite tooling. Aerospace design cycles are long but certification windows are tight — thermoforming compresses the manufacturing timeline.
We extrude sheets from raw pellets in-house — including co-extruded multi-layer sheets with FR cap layers. Complete material traceability from pellet to finished part, critical for aerospace quality documentation.
Aerospace Component Portfolio
From radomes to ground support equipment — every thermoformed component an aerospace program needs, formed in the right material for the application.
RF-transparent thermoformed covers for radar, GPS, communication antennas, and satellite uplink systems. Carefully selected PETG and specialty grades ensure minimal signal attenuation while providing structural protection against rain erosion, bird strikes, and extreme temperature cycling.
Thermoformed sidewall panels, ceiling panels, overhead bin liners, and partition walls for aircraft cabins. Flame-retardant ABS and PC/ABS blends meet FAR 25.853 flammability requirements. Textured finishes eliminate secondary painting operations.
Custom-formed air distribution ducts, HVAC channels, and environmental control system housings for aircraft and aerospace ground support equipment. Complex 3D geometries formed in a single shot eliminate multi-piece assemblies and reduce leak points.
Streamlined external fairings, wing root covers, engine nacelle components, and access panel covers. Thermoformed ASA and ABS provide smooth aerodynamic surfaces with consistent wall thickness for predictable structural performance.
Rugged enclosures for ground power units, maintenance platforms, tool carts, and portable test equipment. Heavy-gauge ABS and HDPE housings withstand tarmac conditions — jet blast, fuel exposure, UV, and impact from handling.
Thermoformed protective housings, transport containers, and test fixtures for satellite components, payload modules, and space-grade electronics. Precision forming ensures repeatable dimensions for jig and fixture applications.
Target Sectors
Every aerospace sector has unique material, certification, and performance requirements. We match the right thermoforming solution to your program.
Interior panels, overhead bin liners, galley components, lavatory modules, and cabin partition walls. Flame-retardant materials meeting FAR 25.853 with Class A surface finishes.
Materials: ABS FR V-0, PC/ABS, Kydex
Parts: Sidewall panels, ceiling panels, galley housings, partition walls
Radomes, antenna fairings, avionics bay covers, and maintenance access panels for fighter jets, transport aircraft, and helicopters. EMI-shielding options available.
Materials: PETG, ABS FR, PC (Lexan)
Parts: Radomes, avionics covers, access panels, equipment housings
Large-format fuselage panels, payload bay covers, and sensor housings for military and commercial UAS platforms. Lightweight construction maximizes endurance and payload capacity.
Materials: ABS, ASA, PETG
Parts: Fuselage shells, sensor housings, payload covers, ground stations
Transport containers, clean room fixtures, test jigs, and protective housings for satellite components. ESD-safe materials available for electronics handling applications.
Materials: ABS ESD, HIPS, PETG
Parts: Transport containers, test fixtures, protective housings, ESD trays
Interior trim panels, instrument panel housings, cargo bay liners, and external fairings for civil and military helicopters. Vibration-resistant mounting designs.
Materials: ABS, PC/ABS, ASA
Parts: Interior trim, instrument housings, cargo liners, fairings
Enclosures for ground power units, maintenance platforms, portable test sets, and fueling equipment. Heavy-gauge forming for tarmac-tough durability.
Materials: ABS, HDPE, ASA
Parts: GPU housings, tool cart covers, equipment enclosures, access panels
Materials for Aerospace
Every material is selected for the specific demands of aerospace — flame retardancy, RF transparency, impact resistance, and temperature performance.
| Material | Aerospace Application | Key Properties | Max Temp |
|---|---|---|---|
| ABS FR V-0 | Interior cabin panels, galley housings, partition walls | Flame retardant, self-extinguishing, UL 94 V-0, low smoke | Up to 80°C |
| PC/ABS | High-impact interior panels, instrument housings | High impact, flame retardant, dimensional stability | Up to 110°C |
| PETG | Radomes, RF-transparent covers, chemical-resistant housings | RF transparent, chemical resistant, good clarity, impact resistant | Up to 70°C |
| PC (Lexan) | Transparent windows, impact shields, lighting covers | Optically clear, 250x stronger than glass, high heat resistance | Up to 130°C |
| Kydex | Aircraft interior panels, seat backs, tray tables | FAR 25.853 compliant, thermoformable, textured finishes | Up to 80°C |
| ASA | External fairings, ground equipment, UV-exposed covers | UV stable 10+ years, weather resistant, color-through | Up to 90°C |
| ABS ESD | ESD trays, satellite component handling, electronics fixtures | Static dissipative, controlled resistivity, cleanroom compatible | Up to 80°C |
We extrude all materials in-house from raw pellets — including co-extruded multi-layer sheets with flame-retardant cap layers. This vertical integration provides complete material traceability from pellet to finished part, critical for aerospace quality documentation and program certification requirements.
Engineering Spotlight
Radomes are one of the most demanding thermoforming applications in aerospace. The cover must be structurally rigid enough to withstand rain erosion and aerodynamic loads, yet RF-transparent enough to allow radar and communication signals to pass through with minimal attenuation. We form radomes in PETG and specialty grades with consistent wall thickness — critical because wall thickness variations cause signal distortion. Our large-format capability allows single-piece radomes exceeding 2 metres, eliminating seam joints that degrade RF performance.
Process Comparison
How vacuum forming compares to other manufacturing processes commonly used for aerospace components.
| Factor | Thermoforming | Composite Layup | Sheet Metal | Injection Molding |
|---|---|---|---|---|
| Tooling Cost | $5K-30K | $2K-15K | $10K-50K | $50K-300K |
| Mold Lead Time | 3-4 weeks | 2-6 weeks | 4-8 weeks | 12-20 weeks |
| Unit Cost (500 pcs) | $$ | $$$$ | $$$ | $$ |
| Part Weight | Light | Lightest | Heavy | Light |
| Flame Retardancy | FR V-0 available | Inherent (some) | Inherent | FR V-0 available |
| Max Part Size | 4m+ | Unlimited | Limited by press | Limited |
| Ideal Volume | 50-5,000/yr | 1-200/yr | 500+/yr | 5,000+/yr |
| RF Transparency | Excellent | Variable | None | Excellent |
Thermoforming is the optimal process for aerospace programs producing 50-5,000 units per year — too many for composite hand layup, too few for injection molding tooling investment.Read the full comparison guide →
Send us your 3D models, drawings, or specifications. We'll recommend the right material, provide a DFM review, and quote your aerospace components — typically within 48 hours.