Polymer Casting
Polymer Casting Capability
Aero Services has extensive experience casting a wide range of polymers for aerospace, rail, automotive, defence, and industrial applications. Our in-house capability supports functional and ergonomic components, with material properties tailored to the application.
Self-Skinning Polyurethane (PU) Foam Components
We manufacture components using self-skinning polyurethane foams, combining a durable outer skin with an energy-absorbing core. Typical products include:
- Armrests
- Bump stops
- Headrests
- Head-strike protection components
Additional Polymer Casting Capabilities
In addition to self-skinning PU foams, Aero Services can cast:
- Rigid polyurethane components
- Closed-cell foam structures
- Silicone components
- Rubber components
These materials are used across applications including seals, protective elements, housings, and functional interfaces.
Tooling & Integration
Polymer casting tooling is designed and manufactured in-house to control geometry, surface finish, and repeatability. This capability integrates with CNC routing, composites, vacuum forming, and assembly operations to support efficient development from prototype through to production.
Assembly, Welding & Spray Painting
Assembly
Aero Services assembles complex systems and structures in accordance with approved design data packs, whether generated in-house or supplied by customers. Our assembly capability supports multi-component systems, modules, and structural/semi-structural assemblies across certified and non-certified programmes.
Welding
MIG and stick welding operations are performed in-house by a qualified welder, supporting tooling manufacture and finished assemblies, including structural frames, brackets, fixtures, and integrated metal-composite assemblies.
Spray Painting & Finishing
Aero Services operates a 7 × 4.5 m automotive spray booth, providing finishing on FRP/composite components, thermoplastics, and steel/metal parts. This supports both cosmetic finishes and protective coatings, enabling delivery in an installation-ready state.
Integrated Manufacturing & Validation Approach
Assembly, finishing, and testing are integrated with our design, composites, vacuum forming, CNC machining, and robotic trimming capabilities—supporting efficient progression from manufacture through verification to final delivery.