Custom Window for Aerospace Industry

Custom Window for Aerospace Industry
Custom Window for Aerospace Industry

At Reliable Formed Plastics, we reverse engineered a Lexan window for an instrument panel on a Black Hawk helicopter from 1:1 digital drawings and modeled the window in 3D software. Custom molds and trim fixtures were also designed and fabricated for our aerospace customer. The part was designed using SolidWorks CAD design 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 military specifications, and shipped. We now manufacture at least 500 of these Lexan windows annually to Mil-Spec standards for delivery to the Southeastern U.S.

Our tooling for the FAI was so precise, that once the first article inspection was completed, the same tooling was used to run production quantities. For further information, contact us directly.

Custom Window for Aerospace Industry
Custom Window for Aerospace Industry
Custom Window for Aerospace Industry
Custom Window for Aerospace Industry

 

Custom Window Specifications

Product Description
Lexan window for instrument panel on a Black Hawk Helicopter
Capabilities Applied/Processes
Primary:
  • Vacuum Thermoforming
  • 5-Axis CNC Routing
Equipment Used to Manufacture Part
SolidWorks: CAD Design Software
Mastercam: CAM Software
Thermwood 5-Axis CNC Router
Custom Vac. Therm. Mold, Custom Trim Fixture
Overall Part Dimensions
Length:15.25"
Width: 13.67"
Height:  .050"
Weight:  ≈6.5oz
Tightest Tolerances
± 0.010"
Material Used
9034 Lexan (Polycarbonate)
Material Finish
Smooth clear
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)
Printable PagePrintable Page Email This PageEmail This Page Back to TopBack to Top