Plastisart specialises in the design and manufacture of plastic parts and assemblies for the indu...
Plastics industry for the aerospace & defense sector Custom plastic components for the most demanding environments
Aerospace and defence share common requirements that define a unique specification in the plastics industry: designing lightweight yet mechanically robust parts, capable of operating in severe environments, extreme temperatures, vibrations, shocks, aggressive chemical agents, all with uncompromising traceability and precision.
Our expertise in aerospace and defence plastics is built on precision CNC machining processes, mastery of advanced polymers and a unique know-how in optical blow moulding. From single reverse-engineered parts to small and medium series, we shape high-performance parts critical to military, space and aeronautical applications.
Why are high-performance thermoplastics increasingly used in this sector ?
The replacement of metal by technical polymers is a fundamental trend in advanced sectors, driven by concrete imperatives of weight reduction and durability.
Polymers such as PEEK, PPS, PEI (Ultem) or carbon fibre-filled polyamides (PA) rival aluminium or titanium. They offer a weight saving 2 to 6 times greater. In civil or military aviation, every kilogram saved reduces fuel consumption and optimises payload. In defence, the lightness of portable or embedded tactical equipment directly improves operational agility in the field.
Furthermore, these materials offer properties inaccessible to metals: inherent thermal and electrical insulation, absence of corrosion, and total chemical inertness against hydrocarbons, hydraulic oils (Skydrol) and decontamination agents.
Design and prototyping
- Comprehensive support, from design to industrialization
- Detailed identification of your technical needs
- Advice on the choice of the most suitable technologies
Examples of parts produced by Plastisart for this sector
Optical glazing and windows
Our historical expertise in precision contact-free blow moulding allows us to produce domes, bubbles and canopies in PMMA and polycarbonate with irreproachable clarity. The absence of optical distortion and contact marks makes these parts indispensable for observation equipment, drone sensors and surveillance systems.
Machined structural parts
CNC machining 3 and 5 axes of advanced polymers allows the design of lightweight structural components with micrometric tolerances. These parts are integrated at the heart of embedded systems, actuators and mechanical interfaces subject to strong vibrations.
Equipment protection and cladding
By thermoforming or RIM injection, we manufacture covers, casings and protective housings for military electronic equipment. These claddings can withstand impacts, extreme thermal cycles from -50°C to +150°C and UV radiation.
Components for control systems
We produce facades, housings and operator interfaces for communication and navigation tools. These parts combine functional design, lightness and compliance with electromagnetic protection standards (EMI shielding).
Reverse engineering and obsolescence management
The lifecycle of military and aeronautical fleets can span many years. Using 3D scanning, we reproduce identical plastic parts that have become obsolete and whose original drawings or manufacturers no longer exist, thereby extending the service life of existing equipment.
The high-performance materials we offer
Aerospace and defence applications require grades whose characteristics far exceed those of standard plastics :
- PEEK (Polyetheretherketone): Continuous thermal resistance up to 250°C, excellent mechanical strength, exceptional behaviour against radiation and fire.
- PPS (Polyphenylene sulphide): Maximum dimensional stability, near-zero moisture absorption and universal chemical resistance.
- PEI (Ultem): High mechanical rigidity and inherent flame retardancy, certified for aeronautical smoke toxicity requirements (FAR 25.853 / UL94 V0).
- PA (Polyamides) glass or carbon filled: Excellent fracture resistance and increased rigidity for the replacement of aluminium die-cast parts.
- Polycarbonate (PC) and aeronautical-grade PMMA: Impact resistance and superior optical transparency for the protection of optronic equipment.
Documentation rigour and material traceability
To meet the requirements of the aeronautical and defence industry, compliance must be absolute. At Plastisart, documentary rigour is an integral part of our industrial protocol.
Every batch of high-performance parts delivered is accompanied by a complete quality assurance file. This file includes material conformity certificates (2.1 and 3.1), records of virgin production batches, dimensional inspection reports by metrology and machine parameter records. This strict management allows our principal contractors to secure their supply chain, validate their airworthiness files and respond with confidence to sectoral certification audits.
Why choose Plastisart for your project ?
In aerospace and defence, the failure of a component is not an option. The reliability of technical plastics is a guarantee of operational safety. Thanks to its experience with sensitive projects, the precision of its machining equipment and its culture of traceability, Plastisart is the ideal trusted partner to support you throughout your project.
Are you looking for a partner for an aerospace and defence plastics project? Or are you looking for a subcontractor to produce high-performance parts in Belgium or France? Contact our teams for a technical feasibility analysis and a personalised quote.
