Thermoplastics Capabilities

Our injection molding, thermoforming and blow-molding processes combined with our value-added general fabrication and assembly capabilities offer one-stop-shop sourcing that can reduce the vendor base of our valued customers.
The use of exotic, high-temperature and filled materials are common at Texstars. Our immense history and collective engineering knowledge are truly uncommon in the aerospace and defense industry.

In-house tooling capabilities

Our in-house tooling capabilities are very convenient for us and our customers. We can control costs and schedules for the fabrication of new tooling. If tool modifications are needed, Texstars offers complete in-house tooling design and fabrication capabilities. Maintenance and tool repair can also be conveniently controlled in-house.
Digital file translation and multiple software format capabilities can be used and depending on production requirements and objectives, composite or metallic tooling can be utilized. This in-house capability allows Texstars to better serve our valued customers.

Customer Base

  • Airbus Industries
  • ATK Alliant Techsystems
  • BAE Systems
  • B/E Aerospace
  • Bell Helicopter
  • Boeing Company
  • Boeing Integrated Defense Systems
  • Boeing Phantom Works
  • Bombardier Canadair
  • CPI Aero
  • Goodrich Aircraft Interior Products
  • Kinkisharyo Limited
  • Lockheed Martin Aeronautics
  • Lockheed Martin Fire Control
  • Lockheed Martin Skunk Works
  • Northrop Grumman Corporation
  • Raytheon Company
  • Spirit AeroSystems
  • Triumph Aerostructures – Vought
  • U.S. Air Force
  • U.S. Army Missile Command
  • Various others

Thermoplastic aerospace products

  • Interior panels
  • Air ducting
  • Housings
  • Stretched acrylic
  • Sabots
  • Rocket pod covers
  • Control surfaces
  • Wing structure components
  • Containers
  • Missile components
  • Covers
  • Glareshields
  • Engine covers
  • Optical laminates
  • Seat components
  • Wing slat components
  • Ordnance components
  • Inlet covers
  • Classified parts

Thermoplastic aerospace processes

  • High-temp thermoforming
  • High-temp injection molding
  • Blow molding
  • Stretched acrylic to MIL-PRF-25690
  • Thermoplastic composite forming
  • Secondary finishing & assembly
  • Advanced coating systems

General fabrication operations

  • Trim/drill
  • Assembly
  • Prime/paint
  • Core cutting
  • Bond/rivet
  • Sand/finish
  • Kit/package

Value-added assembly & secondary fabrication capabilities

Texstars has a unique role in the aerospace industry in that our expertise of multiple lean manufacturing processes is unmatched. Products utilizing composite and thermoplastic materials can be combined with our assembly and secondary fabrication capabilities to yield the next-higher assemblies that today’s airframe manufacturers require.
The infrastructure and capital equipment arranged within our 300,000 total ft2 (27,871 m2) facility offers an extraordinary collection of integration OEMs desire and often require. Value-added, installation-ready assemblies and secondary finishing capabilities have always been a core competency at Texstars

Thermoplastic materials

  • Polycarbonate
  • Peek
  • Polypropylene
  • Radel
  • Ultem
  • Nylons
  • ABS
  • Kydex Acrylic Noryl
  • Acrylic PVC
  • Lexan…and many others

Thermoplastic molding & forming programs of note

Helmets & optical visors for NASA’s Gemini and Apollo astronauts Optical-grade polycarbonate
World’s first all-composite MK-125 missile warhead assembly 30% carbon-filled Ultem
Observation window for Air Force One Optical-grade polycarbonate
Night vision goggle components
30% glass-filled nylon
30% Carbon-filled Ultem
Missile components Noryl
Drone air scoops Texin 4215
Cockpit liners Ultem
Aircraft wing end seals PEEK
Glareshield assemblies Polycarbonate
Observation windows for submersibles Optical-grade polycarbonate
Environmental ducting Polycarbonate
Wingtip lenses Optical-grade polycarbonate
Classified programs Classified