ThermoFormed.
Plastics

Aerofoam designs and manufactures both single leaf and complex bi-fold thermoformed tray tables for the commercial aircraft seating market. Every tool used in our tray table program is designed, engineered, and produced entirely in-house — giving us complete control over quality, lead times, and program support from initial concept through delivery.

Our proprietary vacuum lamination assembly process bonds lightweight thermoformed tray skins to CNC-machined foam cores under precise vacuum pressure — creating an exceptionally rigid tray structure without the weight penalty of conventional construction. Available in recyclable tray skin and foam core options, our tray tables support airline sustainability objectives without compromising on performance or aesthetics. Water-based adhesives are used throughout our assembly process, minimizing VOC emissions and contributing to a cleaner cabin environment.

With multiple dedicated production lines and fully in-house design, tooling, forming, machining, and assembly capabilities, Aerofoam delivers tray table programs at scale with the consistency and precision that commercial aviation demands. Our unique jog feature creates a clean hidden seam between upper and lower shells — and each tray can be finished with 4-color pad printing, laser printing, or hot stamping for airline branding, livery, safety markings, and decorative applications.

Aerofoam designs and manufactures OSU compliant thermoformed seat shells and vertical surfaces for leading aircraft seating manufacturers worldwide. Utilizing our state-of-the-art thermoforming equipment and 5-axis CNC machining centers, we produce components 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 component is delivered as a fully assembled, turnkey unit — bonded with OSU compliant soft-touch foams that provide both a refined aesthetic finish and a tunable haptic experience. Our soft-touch foam layers can be formed and machined to incorporate virtually any design, pattern, or brand element — from contoured shapes to logos — adding a level of customization rarely seen in commercial aviation interiors. Finished in fabrics, synthetic leathers, or suedes, our decorative materials can feature CNC stitching or precision perforations for an added layer of design sophistication.

For programs where acoustic performance is a priority, Aerofoam seat shells can be produced using specialized sound-absorbing foam materials — creating a cocoon-like environment that reduces cabin noise and enhances the overall passenger experience. 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 components 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 and everything in between. Utilizing our state-of-the-art thermoforming equipment and 5-axis CNC machining centers, we form and trim components of any size or complexity with exceptional precision and consistency — working with the full range of FAA-compliant thermoplastic materials to meet exact program performance, weight, and aesthetic requirements.

What sets Aerofoam apart is our multiple configurable assembly cells — purpose-built to add value to thermoformed components and deliver fully assembled, ready-to-install parts directly to the customer's production line. From seat backs and armrests to tray tables and interior panels, our assembly cells integrate Velcro, mounting brackets, literature pockets, and any other required components — so that every part arrives line-ready, reducing handling, eliminating extra production steps, and compressing lead times for just-in-time programs.

With in-house design, development, tooling, thermoforming, machining, and assembly all under one roof, Aerofoam is a single vertically integrated source for thermoformed aviation interior components of any kind.