Custom Cover for the Aerospace Industry

Custom Cover for the Aerospace Industry
Custom Cover for the Aerospace Industry

With our ability to produce top quality products at moderate volumes with low tooling costs and short lead times, Reliable Formed Plastics has a strong history in manufacturing custom solutions for the aerospace industry. The opaque cover highlighted here is a good example of a thermoformed product that we produce on an ongoing basis for a top tier company in the global aviation industry.

The initial phase of the project involved creating a 3D solid model that we designed from the customer-supplied 1:1 drawing and a sample part. In addition to designing and machining the thermoforming mold, we created two custom trim fixtures to ensure consistent part quality. Material of construction was Boltaron® 6800, a high strength, abrasion- and chemical-resistant ABS/PVC alloy designed to meet FAA flammability requirements.

After we built the tooling and programmed the process controls, we produced a part for First Article Inspection, which served to validate that we were capable of thermoforming a conforming product that met all of the engineering and design requirements. Once that was approved, our production processes included thermoforming, trimming the covers on our 5-axis CNC routers, marking them for identification purposes, and packaging them according to Mil-spec standards. Quality assurance involved visual inspection while forming as well as dimensional verification during the CNC process.

When completed, the cover measured 14.66” in length x 4.75” in width x 3.25” in height and weighed approximately 3.2 oz. Our thermoforming expertise and attention to detail enabled us to meet the ±0.010” tolerance requirements of the customer specification. After the initial order of 500 units, we continue to produce them at the same rate on an annual basis.

If you are interested in learning more about this project or our aerospace industry qualifications, contact us today.

Custom Cover for the Aerospace Industry
Custom Cover for the Aerospace Industry
Custom Cover for the Aerospace Industry
Custom Cover for the Aerospace Industry
Custom Cover for the Aerospace Industry
Custom Cover for the Aerospace Industry
Custom Cover for the Aerospace Industry
Custom Cover for the Aerospace Industry

 

Custom Cover Specifications

Product Description
Opaque Cover for Aerospace Industry
Capabilities Applied/Processes
Primary:
Thermoforming & CNC Routing / Trimming
  • Vacuum Thermoforming
  • 5-Axis CNC Routing
Equipment Used to Manufacture Part
SolidWorks: CAD Design Software
Mastercam: CAM Software
Thermwood 5-Axis CNC Router
Custom Designed Vacuum Thermforming Mold
Two Custom Designed 5-Axis Trim Fixtures
Overall Part Dimensions
Length:14.66"
Width: 4.75"
Height:  3.25"
Weight:  ≈3.2oz
Tightest Tolerances
± 0.010"
Material Used
Boltaron 6800
Material Finish
Opaque Material
Part Marked
Packaged to Military Spec.
In process testing/inspection performed
Dimensional verification during CNC Process
Visual Q.C. during Forming
Industry for Use
Aerospace
Volume
Est. 500 per Year
Delivery Location
Southeastern U.S.
Standards Met
Mil-spec ( Military as required)

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