Radome Thermoforming
We heat and vacuum-form plastic sheets into precise radome enclosure shapes using eight thermoforming machines ranging from 2'x3' to 5'x9', producing RF-transparent, weather-resistant housings to exact drawing specifications.
Hill Plastics has specialized in precision radome thermoforming for the telecommunications industry since 1977. Our Lewisville, TX facility houses eight thermoforming machines and advanced CNC trimming centers to produce RF-transparent, weather-resistant radome enclosures to exact specifications—serving OEMs and telecom engineers nationwide with low-cost tooling and fast turnaround.
From prototyping to high-volume production, we deliver precision-formed radome enclosures and supporting services for telecom and aerospace applications.
We heat and vacuum-form plastic sheets into precise radome enclosure shapes using eight thermoforming machines ranging from 2'x3' to 5'x9', producing RF-transparent, weather-resistant housings to exact drawing specifications.
We design and fabricate low-cost wood or polyurethane prototype tooling and production-grade aluminum molds, enabling rapid iteration and cost-effective radome tooling from concept through production approval.
Our two 5'x10' CNC trimming centers perform precision contour cutting, edge finishing, and fastener preparation on radome parts, delivering clean, dimensionally accurate, assembly-ready enclosures every time.
We produce radome prototypes quickly from low-cost wood or polyurethane tooling, typically delivering master patterns within a few weeks so engineers can evaluate fit, function, and RF performance before committing to production tooling.
Our 4'x7' rotary thermoforming machine cycles 2.5 times faster than standard single-station equipment, enabling cost-competitive, quality-controlled high-volume radome production runs at competitive pricing.
Our sales and engineering team evaluates RF transparency, UV resistance, impact strength, and environmental requirements to recommend the best plastic material—ABS, ASA/ABS, HDPE, PETG, or others—for your radome application.
Our engineering team works with your drawings and performance requirements—including RF transparency, UV resistance, and environmental ratings—to recommend the optimal plastic material and tooling approach for your radome application.
See how Hill Plastics has delivered precision radome solutions for telecom, aerospace, and OEM clients across the country.
"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 been the trusted radome thermoforming partner for engineers and purchasing teams across the United States.
Founded in 1977 near Dallas/DFW, our team—with staff averaging 20+ years of tenure—brings unmatched thermoforming and radome fabrication knowledge to every project.
We have a decades-long track record supplying radome enclosures to the telecommunications industry, trusted by major telecom OEMs and antenna manufacturers across the country.
Our wood and polyurethane prototype tooling approach minimizes upfront investment, letting you validate your radome design quickly before committing to production aluminum tooling.
From initial design consultation and material selection through CNC trimming, quality control, and fulfillment, we manage the full production workflow under one 20,000+ sq ft roof in Lewisville, TX.
Our experienced sales and engineering team guides every radome project from concept to completion.
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.
A radome (radar dome) is a weatherproof structural enclosure that protects an antenna or radar system while remaining transparent to the radio frequencies the antenna transmits and receives. It shields sensitive electronics from wind, rain, UV radiation, ice, and physical impact without degrading signal quality. Plastic thermoformed radomes are widely used in telecommunications towers, aviation, marine, and military antenna systems due to their lightweight and cost-effective RF-transparent properties.
Talk to our engineering team for a free consultation and project quote.
Hill Plastics ships custom thermoformed radomes and plastic enclosures to OEMs, telecom companies, and manufacturers across the United States.
Nationwide USA
Service Area
20,000+ Sq Ft
Manufacturing Facility
Mon–Fri, 7AM–4:30PM
Business Hours
Contact us to discuss your project requirements and get a quote for delivery anywhere in the US.
Serving OEMs and telecom clients since 1977.
Advanced design and CNC interface for precision parts.
Preferred vendor for aerospace, telecom, and OEM manufacturers.
Share your radome specifications, drawings, or project requirements with our engineering team and we'll respond with a detailed quote and timeline. We work with OEMs, telecom companies, and product developers across the United States.
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.