General Plastics Mfg. Co.
4910 Burlington Way
Tacoma , WA 98409 US
In the Making: Padded and Flexible Parts for Aircraft Interior Applications
Extending from the flight deck in the fore to lavatories in the aft, General Plastics’ flexible polyurethane foam parts play integral yet unsung roles in today’s aircraft. While few prompt even a second thought from passengers, our build-to-print flight deck and passenger cabin molded parts have been required in the aircraft interior design engineers’ specifications for more than four decades.
Within the flight deck, our parts (incorporating metallic hardware as warranted) provide durable padding in such applications as heads-up display covers, headliners, post pads, kick strips and assist handle covers. General Plastics also fabricates and machines a wide array of other high-quality, custom-molded parts from our unique formulations to fulfill airframe manufacturers’ exacting requirements. Within the passenger cabin, we produce parts for walls and ceilings, class dividers, overhead stow bins, food-service galleys and lavatories.
In this blog post, we’ll highlight three particular interior applications as part of our parts and sheet stock programs.
Our custom-molded armrest pads, which could be used in the flight deck and passenger cabin, are produced from our LAST-A-FOAM® WSF-1121 Impact Energy Absorption high-density flexible foam. This integral-skin, open-cell polyurethane foam system offers numerous advantages:
- Safety – The foam is flame-retardant and self-extinguishing.
- Parts are molded to each customer’s exact specifications.
- Its toughness delivers tremendous durability and impact-absorbing padding.
- Because the foam is self-skinning, parts come out of the mold with the desired texture, in the specified color and painted for a long-lasting finish, so there’s no need for the added step and expense of adding a protective material.
As with any build-to-print program, our team is ready to help you solve challenges and support your efforts from part and tool design to mold tooling, and every step in parts production. Where appropriate, we are also best-positioned to custom-formulate foam systems in order to supply parts with the precise physical properties and attributes you need.
General Plastics’ Foam-Comb is a lightweight honeycomb-urethane gap filler used in aerospace and aviation interior fabrications. This open-cell polyurethane product couples our flexible foam with Nomex® honeycomb material, where the resulting material – the Foam-Comb – is stronger than the honeycomb, but adds little weight. It also provides a flexible cushion between panels that repeatedly expand and contract, reducing vibration and maintaining a seal between the surfaces.. These qualities make it particularly useful within the passenger cabin and in other areas where noise reduction is desirable. Typical aviation gap filler applications include:
- Overhead storage bins
- Passenger cabin dividers
- Overhead stow bins
Heads-up Display Cover
Another molded part General Plastics produces are the heads-up display covers located in the flight deck. Produced from the same WSF-1121 flexible foam as our molded armrests pads, these covers hold the dual heads-up display and the overhead panel, which houses various electronics that control systems throughout the plane. Due to the foam’s self-skinning characteristic, designers have artistic freedom in the desired texture and color. The parts are ready for their final paint coating right out of the mold.
Assurance through certification
General Plastics’ customers depend on the highest quality materials and parts. Our quality assurance program and its products conform to numerous aerospace and defense industry requirements and rigorous quality systems. These include:
- Boeing Company D6-82479
- BMS 8-133 – Flame-Retardant Rigid Urethane Foams (core materials)
- BMS 8-350 – Integral Skinning Flexible Urethane Foam and Paint for Molded Products
- BMS 8-39 – Flexible Urethane Foams
We are certified to ISO 9001:2008/AS9100C and ITAR-compliant, with a segregated, controlled-access ITAR assembly room for military parts.
A Message from General Plastics Mfg. Co.
As Seen In CompositesWorld
Composite sandwich panels enable flexibility in medical table design
Polyurethane foam core provides a cost-effective option for ACP Composites’ specialized medical positioning table design.
CAMX 2020 exhibit preview: General Plastics
General Plastics Manufacturing Co. is showcasing its LAST-A-FOAM core products, custom molding capabilities and high-temperature, low-CTE tooling board.
Composites suppliers, fabricators respond to coronavirus
Companies across the composites industry supply chain share how the COVID-19 pandemic is affecting their businesses, and how they are available to help.
CAMX 2019 exhibit preview: General Plastics
General Plastics Manufacturing Co. is showcasing its new LAST-A-FOAM FR-4800 tooling board at its CAMX 2019 booth.
CAMX 2018 preview: General Plastics
General Plastics (Tacoma, WA, US) is featuring its new high-temperature, low-CTE LAST-A-FOAM FR-4800 tooling board.
General Plastics launches ultrahigh-temperature tooling board
General Plastics Mfg. Co. (Tacoma, WA, US) expanded its line of high-temperature tooling board materials with the introduction of LAST-A-FOAM FR-4800, an autoclave-capable, high-density epoxy-urethane foam designed for master plug manufacturing, tool proofing, vacuum form tooling, pattern making, and short-run production tooling applications.
CAMX 2017 preview: General Plastics
General Plastics Mfg. Co. (Tacoma, WA, US) is showcasing its new LAST-A-FOAM RF-2200, a lightweight material that provides an RF-transparent protective layer for radome and antenna applications.
JEC World 2017 exhibit preview
JEC World will be held March 14-16 in Paris. CW previews some of the products and technologies that will be at the show.
JEC World 2016, the full report
CompositesWorld's editors report on the technologies and products that caught our eye at JEC World 2016, in early March.
Composites 101: Tooling
Composite parts are formed in molds, also known as tools. Tools can be made from virtually any material. The material type, shape and complexity depend upon the part and length of production run. Here's a short summary of the issues involved in electing and making tools.
CFRP camera boom enables safe spill inspection
NONA Composites’ 32m REACH structure meets tight remediation schedule at DoE radioactive waste storage site.
Composite tooling without oven or autoclave
No Oven No Autoclave technology has been demonstrated in tooling for NASA, including multiple thermal cycles and use for curing epoxy infused out-of-autoclave parts.
Pierce County trains skilled workers through collaborative curriculum building
Bruce Kendall, the president and CEO of the private, nonprofit Economic Development Board (EDB) for Tacoma-Pierce County (Wash.), reports on the success of a collaborative training curriculum development program that produces skilled workersfor the aerospace industry.
Tooling boards improve processes
In the composites industry, many parts are the product of one-off or few-of-a-kind production programs. In response, tooling material suppliers today provide an increasing variety of relatively inexpensive materials grouped under the heading of tooling board.
SAMPE 2009 Product Showcase
Showgoers at the SAMPE 2009 Conference and Exhibiton in Baltimore, Md. found many suppliers undeterred by poor economic news.
Taking Up Tooling Boards
Tooling Board ManufacturersEpoxy and polyurethane tooling boards are a standby for creating models or low-run-production tooling.
SAMPE 2005 Product Showcase
SAMPE's U.S. Symposium and Exhibition highlights technological innovation and market expansion.
Blast protection for large structures
Hardening of public buildings against terrorist threats represents a potentially huge market for antiballistic composites.