In modern aerospace applications, high-performance plastic components — from seals and bushings to electrical insulators — are increasingly replacing metal where weight, corrosion resistance, and precision are major factors. Aerospace plastic machining allows engineers to achieve tight tolerances, complex geometries, and repeatable performance for both flight-critical and ground-support parts.
In this article, we’ll cover the key considerations for selecting materials, machining strategies, and design best practices, as well as what OEMs can expect when partnering with Ensinger for precision aerospace plastic components.
Why Aerospace Is Shifting Toward Machined Plastic Components
Aerospace engineers increasingly favor machined plastic parts to meet the dual demands of performance and weight reduction. Replacing metal with high-performance plastics like PEEK, PAI, and PTFE can cut component weight while maintaining strength and dimensional stability.
Plastics also offer superior corrosion resistance and improved thermal or electrical insulation, making them ideal for both structural and non-structural applications. Machined plastics provide flexibility in design that metals often cannot, enabling more intricate geometries, integral features, and part consolidation.
Key Considerations in Aerospace Plastic Machining
Machining aerospace plastics requires attention to material behavior under heat and mechanical stress. Achieving tight tolerances on soft or thermally sensitive materials demands precise spindle speeds, tooling strategies, and controlled environments. Surface finish, concentricity, and dimensional stability are critical, particularly for components exposed to temperature extremes.
Proper tooling selection, cutting parameters, and chip management ensure that high-performance plastics are machined accurately without causing stress, deformation, or contamination. Early design review helps prevent issues and streamlines the transition from prototype to production.
Material Selection for Aerospace Applications
Choosing the right material is essential for performance and regulatory compliance. Common options include PEEK, Ultem®, Torlon®, and fluoropolymers, each offering a balance of strength, chemical resistance, and thermal stability.
Designers must also consider flame resistance (FAR 25.853), outgassing behavior, thermal expansion, and dielectric properties, especially for flight-critical components. Ensinger supports OEMs in selecting the optimal polymer for specific operational environments, ensuring that the material meets functional, regulatory, and longevity requirements.
Inspection, Documentation, and Lot Traceability
Traceability and documentation are essential in aerospace. Ensinger provides First Article Inspection (FAI) and PPAP documentation when required, along with serialization, detailed inspection records, and full lot traceability.
Our internal quality management system ensures that each part meets customer specifications and regulatory standards. Engineers and procurement teams can rely on consistent reporting and documentation to simplify audits and maintain compliance throughout the supply chain.
Work with a Trusted Partner in Aerospace Plastic Machining
Ensinger combines precision machining, AS9100D certification, and extensive experience with high-performance plastics to deliver aerospace components that meet the strictest standards. From initial material selection to final inspection and traceability, our team supports engineers and OEMs through every stage of the machining process.
Reach out to our team today to discuss your next aerospace plastic machining application and see how we can help bring your design from concept to production.