Hill Plastics delivers precision aerospace thermoforming services trusted by leading aviation and defense manufacturers. From lightweight radome enclosures to custom interior components, our 45+ years of expertise ensures dimensional accuracy, FAA-compliant material selection, and cost-effective production at any volume — from rapid prototypes to full production runs.
Comprehensive thermoforming and fabrication solutions engineered to meet the demanding tolerances of aerospace and aviation applications.
Custom vacuum and heavy-gauge thermoforming using aerospace-compatible materials such as High-Temperature ABS and UV-Resistant ASA/ABS. Eight machines ranging from 2'x3' to 5'x9' support precision aerospace component production at any volume.
Precision CNC trimming and cutting of thermoformed aerospace parts to exact drawing specifications. Two 5'x10' CNC trimming centers ensure clean edges, repeatable accuracy, and assembly-ready components for aviation OEMs.
Custom aerospace molds produced from aluminum, polyurethane, or wood tooling. Prototypes can be formed quickly from low-cost tooling, with production molds cast in aluminum for long-run dimensional consistency.
Full-service fabrication including precision drilling, heat bending, bonding, fastener installation, and edge finishing for aerospace enclosures, machine guards, and custom OEM parts — all trimmed to drawing specifications.
Rapid aerospace prototypes produced from low-cost wood or polyurethane tooling in just a few weeks. Ideal for design review and functional evaluation before committing to full aluminum production tooling.
Rotary thermoforming technology with cycle times 2.5x faster than standard single-station machines, enabling cost-effective, high-volume aerospace component production with rigorous quality control at every stage.
Our engineering team evaluates your aerospace component requirements — including FAA-relevant factors like temperature resistance, chemical resistance, and structural durability — to recommend the optimal thermoforming material and tooling strategy using SolidWorks CAD.
See how Hill Plastics delivers precision thermoformed components that meet the rigorous demands of aviation and defense manufacturers.
"Great value, family business, personal attention. Over the years, Cody, Brad, and Aubrey have become valued associates in my small enterprise. Willing to tackle design challenges. Get-her-done communications. Outreach to additional sources of expertise. These folks understand the inventive process. Cody for example is a Kickstarter supporter and is familiar..."
"Hill Plastics did a great job creating a substitute back window for my RV. I have a portable mini-split air conditioner that I use in extremely hot weather to supplement my RV’s own cooling power. The mini-split has an inside unit that blows the cold air and an outside condenser..."
"Great value, family business, personal attention. Over the years, Cody, Brad, and Aubrey have become valued associates in my small enterprise. Willing to tackle design challenges. Get-her-done communications. Outreach to additional sources of expertise. These folks understand the inventive process. Cody for example is a Kickstarter supporter and is familiar..."
"Hill Plastics did a great job creating a substitute back window for my RV. I have a portable mini-split air conditioner that I use in extremely hot weather to supplement my RV’s own cooling power. The mini-split has an inside unit that blows the cold air and an outside condenser..."
"Great value, family business, personal attention. Over the years, Cody, Brad, and Aubrey have become valued associates in my small enterprise. Willing to tackle design challenges. Get-her-done communications. Outreach to additional sources of expertise. These folks understand the inventive process. Cody for example is a Kickstarter supporter and is familiar..."
"Hill Plastics did a great job creating a substitute back window for my RV. I have a portable mini-split air conditioner that I use in extremely hot weather to supplement my RV’s own cooling power. The mini-split has an inside unit that blows the cold air and an outside condenser..."
We combine decades of thermoforming expertise with advanced manufacturing capabilities to deliver aerospace-grade plastic components on time and on budget.
Founded in 1977, our team brings over four decades of precision thermoforming experience to every aerospace component we produce.
Eight thermoforming machines, two 5'x10' CNC trimming centers, and a rotary thermoformer that runs 2.5x faster — all under one 20,000 sq ft roof.
From initial design and material selection to prototyping, tooling, production, and delivery — we manage your entire aerospace component project from idea to fulfillment.
Trusted by aerospace and aviation brands including Southwest Airlines and Enflite, our components meet the quality standards the industry demands.
Experienced engineers and sales professionals dedicated to your aerospace thermoforming success.
Sales & Engineering Team
Brad Hill brings deep expertise in plastic thermoforming design and materials engineering to every customer project. As a key member of Hill Plastics' sales and engineering team, Brad specializes in helping clients navigate the complexities of material selection—evaluating cost, impact requirements, durability, tensile strength, chemical resistance, and environmental factors to identify the optimal PS or HIPS grade for each unique application. He works closely with customers from initial concept through prototype approval, offering guidance on tooling design, process optimization, and production planning. Brad's hands-on approach ensures that every thermoformed component is engineered for performance, manufacturability, and cost-effectiveness. His commitment to collaborative problem-solving and technical precision has made him a trusted advisor to OEM manufacturers, aerospace clients, and medical device companies nationwide. With a focus on delivering turnkey solutions that meet exact specifications, Brad exemplifies Hill Plastics' dedication to quality, innovation, and customer success.
Sales & Engineering Team
Cody Hill is a skilled plastics engineer and sales professional with a passion for transforming customer ideas into precision-manufactured reality. As part of Hill Plastics' dedicated sales and engineering team, Cody provides expert consultation on product design, material selection, and tooling strategy for custom thermoforming projects. He leverages advanced CAD tools like SolidWorks to collaborate with clients on design refinements, ensuring optimal part geometry, wall thickness distribution, and draft angles for successful vacuum forming. Cody's technical knowledge spans the full spectrum of PS and HIPS materials, enabling him to recommend the best plastic grade based on application-specific demands such as impact resistance, rigidity, clarity, and cost. From rapid prototyping using low-cost tooling to scaling up for high-volume production runs, Cody guides customers through every phase of the manufacturing process with transparency and attention to detail. His proactive communication style and commitment to delivering on-time, on-budget results have earned him the trust of clients across aerospace, telecommunications, industrial equipment, and medical device sectors.
Aerospace components are commonly made from high-performance thermoplastics selected for their strength-to-weight ratio and environmental resistance. Hill Plastics works with materials including High-Temperature ABS, UV-Resistant ASA/ABS, KYDEX, HDPE, and PETG. Material selection is based on factors such as temperature resistance, impact requirements, chemical exposure, and FAA-relevant durability standards for the specific application.
Speak directly with our engineering team for expert guidance and a tailored quote.
Hill Plastics ships precision thermoformed aerospace components to customers across the entire United States from our Lewisville, TX facility.
Nationwide USA
Service Area
20,000+ Sq Ft
Manufacturing Facility
1977 (45+ Years)
In Business Since
We deliver precision aerospace thermoformed components anywhere in the United States.
Trusted aerospace thermoforming manufacturer since 1977.
Advanced CAD and CNC interface capability for precision parts.
Trusted by Southwest Airlines, Enflite, and LifePort.
Share your component requirements and our engineering team will provide an expert assessment and competitive quote. We respond promptly to all aerospace and aviation inquiries.
For immediate assistance, feel free to give us a direct call at +1 972-436-9717. You can also send us a quick email at sales@hillplastics.com.
For immediate assistance, feel free to give us a direct call at +1 972-436-9717. You can also send us a quick email at sales@hillplastics.com.