Fabrication Process

The aircraft seat cushion fabrication process follows four steps, from design and development to final product.

STEP 1: Design & Development

Our Engineering/Design department can create new cushion designs for your aircraft seating, as well as work from samples, drawings, or solid models. During this time the types of foam materials are defined to achieve a customer's comfort level, styling and weight considerations.

STEP 2: Testing

Working with the requirements set forth by the customer, the cushion designs are tested for comfort, download and flammability as required by the F.A.A.

STEP 3: Production

During this step we define the most efficient and cost effective way to produce cushions. We utilize CNC fabrication equipment including Shape Profilers, Routers, Fast Wire Cutting, Water Jet cutting, and Foam Thermoforming to name a few.

STEP 4: Final Product

This is the finished aircraft seat cushion that has been designed, tested, certified and ready for fireblock cover installation.

Cushion Fabrication

Our facility houses state-of-the-art CNC machinery as well as plastic thermoforming and pressure forming equipment. The fabrication of foam cushions for aircraft seating allow us to take comfort to a new level while keeping weights to a minimum.

Water Jet Cutting

We water jet cut all types of foam materials. This process uses pressurized water working at 55,000 PSI to cut through the foam. It follows a computer-generated pattern and can produce complex shapes and cavities very quickly and efficiently.

Thermoforming

We thermoform all types of cross-linked polyethylene foams. Our thermoforming capabilities vary from simple tray liners to very complex designs.

CNC Routing

Our CNC allows us to route all polyethylene and closed cell foams, including E.P.S. This process uses a high-speed router that follows AutoCAD drawings to produce complex foam cavities.

Profiling

Our profiler has a 82' by 96' table, and utilizes hot wires to produce repeated complex shapes throughout a bun of material. The profiler works with all foams.

Aircraft Seat Foam