Texstars has a wealth of engineering-grade thermoplastics expertise and experience with a variety of processes. Our injection molding, thermoforming, blow molding and secondary foaming operations are complemented with general fabrication and kitting of next-higher assemblies our valuable customers require.




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


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


Thermoplastic Materials

  • Polycarbonate
  • Peek
  • Polypropylene
  • Radel
  • Ultem
  • Nylons
  • ABS
  • Kydex Acrylic Noryl
  • Acrylic PVC
  • Lexan
  • Many others

General Fabrication Operations

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

Value-added Assembly & Secondary Fabrication Capabilities

Value-added, installation-ready assemblies and secondary finishing capabilities have always been a core competency at Texstars. 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 from within our 300,000 total ft2 (27,871 m2) facility.


In-House Tooling Capabilities

Our in-house tooling capabilities are very convenient for 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. Depending on production requirements and objectives, composite or metallic tooling can be utilized.


Thermoplastic Molding & Forming Programs

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