Hill Plastics delivers precision-engineered custom tooling and thermoformed plastic components built to the exacting standards of the defense and military sector. From low-cost prototype tooling to high-volume aluminum production molds, our Lewisville, TX facility supports mission-critical applications with repeatable accuracy, rigorous quality control, and over 45 years of manufacturing expertise.
Comprehensive plastic tooling and fabrication solutions engineered to meet the strict tolerances and durability demands of defense applications.
Custom molds crafted from aluminum, polyurethane, and wood using advanced CNC machinery and SolidWorks design software. From low-cost prototype tooling to precision production molds, we support every stage of defense component development.
Eight thermoforming machines ranging from 2'x3' to 5'x9' produce custom defense enclosures, radome housings, and OEM components from high-performance materials including High-Temp ABS and UV-resistant ASA/ABS.
Two 5'x10' CNC trimming centers deliver precise contour cutting, edge finishing, precision drilling, and fastener preparation on thermoformed and fabricated defense parts to exact drawing specifications.
Full-service fabrication including heat bending, bonding, riveting, threaded inserts, and assembly operations. Ideal for custom defense enclosures, machine guards, and assembly-ready OEM components requiring zero-compromise finishing.
Rapid prototypes produced from low-cost wood or polyurethane tooling, typically ready within weeks. Prototypes are machined to print specifications for design review and functional evaluation before committing to full production tooling.
A 4'x7' rotary thermoforming machine running 2.5x faster than standard single-station equipment enables cost-effective, quality-controlled high-volume runs of defense parts from thousands to tens of thousands of units.
Our sales and engineering team—Brad and Cody Hill—work directly with defense engineers and procurement teams to review part requirements, functional specs, material needs, and regulatory tolerances unique to military applications. We translate your requirements into a clear manufacturing plan.
See how Hill Plastics has helped defense manufacturers and military OEMs meet demanding specifications on time and on budget.
"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..."
For over four decades, Hill Plastics has earned the trust of engineers and procurement teams in the defense sector by delivering precision, reliability, and cost-effective manufacturing.
Founded in 1977 with staff averaging 20+ years of tenure, our team understands the uncompromising precision that defense and military component manufacturing demands.
We work with High-Temp ABS, UV-resistant ASA/ABS, KYDEX, and HDPE—materials selected to perform in demanding military environments, from arid Southwest conditions to field deployment.
From first design consultation through prototype approval, production tooling, CNC finishing, and final shipment, our 20,000 sq. ft. Lewisville, TX facility handles every step in-house.
Eight thermoforming machines and a rotary thermoformer running 2.5x standard cycle speeds allow us to serve defense contractors and OEMs across the U.S. with short-run or high-volume orders.
Experienced engineers and designers dedicated to precision defense manufacturing.
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.
Hill Plastics produces a wide range of defense and military plastic components including custom enclosures, radome housings, equipment covers, machine guards, custom OEM parts, and material handling trays. Using thermoforming, vacuum forming, CNC trimming, and plastic fabrication, we manufacture parts to exact drawing specifications from materials engineered to perform in demanding military environments.
Speak with our engineering team for a no-obligation consultation on your defense manufacturing project.
Based in Lewisville, TX, Hill Plastics serves defense contractors and military OEMs across the United States.
Nationwide U.S.
Service Coverage
20,000+ Sq. Ft.
Facility Size
45+ Years
Years in Business
We ship precision defense components to contractors and OEMs across the entire United States.
Serving defense and industrial manufacturers since 1977.
Advanced design and CNC interface using SolidWorks software.
Perfect 5-star rating reflecting quality and customer satisfaction.
Submit your project details and our engineering team will respond with material recommendations, tooling options, and a competitive quote tailored to your defense manufacturing requirements.
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.