ThermoFormed.
Plastics

Aerofoam designs and manufactures both single leaf and bi-fold thermoformed tray tables for commercial aviation interiors. Our fully integrated in-house production line — spanning design, development, tooling, and manufacturing — gives us complete control over quality, lead times, and program support from initial concept through delivery.

Our proprietary vacuum lamination system bonds lightweight thin-gauge thermoformed shells to our CNC-machined foam cores under precise vacuum pressure, creating a remarkably rigid tray structure without the weight penalty of heavier conventional shells. Combined with our 5-axis CNC machining centers and unique jog feature — which creates a clean hidden seam between upper and lower shells — Aerofoam tray tables deliver the structural integrity, refined aesthetics, and long-term in-service performance that commercial aviation programs demand.

Aerofoam designs and manufactures thermoformed seat backshells for leading aircraft seating manufacturers worldwide. Utilizing our brand new state-of-the-art thermoforming equipment and 5-axis CNC machining centers, we produce seat backshells with exceptional consistency, tight tolerances, and the surface quality demanded by top-tier airline interior programs — working from 3D CAD data or an existing part to meet exact customer specifications.

Each seat backshell can be delivered as a fully assembled, turnkey component — complete with Velcro, mounting brackets, literature pockets, and any additional hardware required for installation. This eliminates extra production steps on the customer's assembly line, making Aerofoam the ideal supply partner for just-in-time production programs. From receipt to installation, our line-ready backshells reduce handling, compress lead times, and simplify inventory management.

Aerofoam operates a full-service thermoforming facility capable of producing the complete range of aircraft interior components — from small precision detail parts through to full cabin sidewalls. We work with all types of FAA-compliant thermoplastic materials, selecting the right material for each application based on performance requirements, weight targets, and customer specifications.

Our brand new state-of-the-art thermoforming equipment and 5-axis CNC machining centers give us the capability to form and trim components of any size or complexity with exceptional precision. With in-house design, development, and tooling capabilities, we support programs from initial concept through production — offering customers a single, vertically integrated source for thermoformed aviation interior components of every kind.