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 Specifications
- Product Description
- Lexan window for instrument panel on a Black Hawk Helicopter
- Capabilities Applied/Processes
- 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
- Tightest Tolerances
- ± 0.010"
- Material Used
- 9034 Lexan (Polycarbonate)
- Material Finish
- Smooth clear
Packaged to Military Spec.
- In process testing/inspection performed
- Dimensional verification during CNC Process
Visual Q.C. during Forming
- Industry for Use
- Est. 500 per Year
- Delivery Location
- Southeastern U.S.
- Standards Met
- Mil-spec ( Military as required)