5 mm ASA Display Shells Vacuum Forming for Aerospace Interiors

Vacuum formed display shells are used across aerospace interiors because they can be produced without the tooling spend of injection moulding and without the weight of sheet metal. This page covers how 5 mm ASA sheet is formed for aerospace interiors, what tolerances are realistic, and what has to be on the drawing before tooling starts.

The route below is the one used for most of the display shells shipped from this plant: sheet is heated on the forming machine, drawn over an aluminium or composite mould, cooled on a jig, then trimmed on a 5-axis router. For display shells the sheet gauge is selected from the load case rather than from habit, and ASA is the material most often specified for this combination.

Typical specification

Where these parts are used

• seat back shells for aerospace interiors
• galley liners for aerospace interiors
• lavatory panels for aerospace interiors
• stowage bin trays for aerospace interiors
• display shells in general aerospace interiors builds

How the part is made

1. Drawings are reviewed and a manufacturability report is issued with wall thickness, draft and radii marked up.
2. Tooling is cut: aluminium for production volumes, composite or printed moulds for samples and first articles.
3. Sheet is dried when the material needs it, then heated to forming temperature on the machine.
4. The sheet is formed over the mould with vacuum and, where the draw is deep, with plug assist.
5. The part cools on a jig so the shape is held while the material stabilises.
6. Trimming is done on 5-axis routers or with a dedicated trim fixture to meet the drawing.
7. Parts are inspected, fitted with inserts or hardware if required, packed and shipped.

Material notes: ASA

ASA keeps its colour and surface under UV better than ABS, which suits outdoor covers that are not painted.

Design tips for this part

• use corner radii of at least three times the sheet thickness to avoid thinning
• hold the draw ratio near 1:1 for deep parts, or specify plug assist
• call out the finish on the drawing: mould texture, paint, or as-formed gloss
• avoid sharp steps in the mould, which show as chill marks on the finished surface
• keep a draft angle of at least 3 degrees on vertical walls so the part releases cleanly

Quality and inspection

Moulds, trim fixtures and programmes are stored against the part number, so a repeat order matches the first batch. Batch releases carry a dimensional report, material certificate and, where agreed, PPAP or ISIR documentation.

Cost and lead time

Tooling is the main cost driver at low volume, so a 5 mm display shells for aerospace interiors is usually quoted with a composite or printed mould first and the aluminium tool cut once the design is frozen. That keeps the first article cost low and gives a real part to test before the production tool exists. The result is better appearance compared with the alternatives, and a piece price that stays stable across repeat releases.

• Sample tooling: 7–15 working days
• Production tooling: 3–4 weeks
• Repeat orders run on stored tooling with no new proving run

Frequently asked questions

What quantities make sense?

Vacuum forming pays off from roughly 25 pieces up to several thousand a year. Below that, printed or composite tooling keeps the setup cost low.

What do you need to quote?

A 3D file or drawing, the material if it is fixed, the annual quantity and the finish. Photos of the current part are enough for a first estimate.

Do you supply certificates?

Material certificates, dimensional reports and flame retardancy or food contact declarations are issued with the shipment where the specification requires them.

Getting started

Send the drawing or a photo of the current display shells with the quantity and the finish. The first reply is a manufacturability review with the wall thickness, material and a quotation, so the decision is made on facts rather than on a price alone.