The aircraft lavatory toilet shroud presented a problem that many thermoformers would not want to touch. The existing manufacturing method relied on drape forming, a labor-intensive process that required multiple people to handle and shape heated plastic by hand. It was slow, difficult to control, and not well-suited for repeatable production. For the customer, that created mounting pressure around labor, quality, output, and overall long-term viability.
The Challenge
The customer needed a better way to produce an aircraft lavatory shroud that had been formed and trimmed largely by hand. The old process required several operators to heat a large plastic sheet, carry it into place, and manually maneuver it over the tool. That approach was not only inefficient but also created variation from part to part that made scaling production more difficult. The prior supplier was struggling with the workload, economics, and consistency required as demand increased.
What made the part especially challenging was its geometry. The part was effectively being “crafted” by hand because a conventional approach would not reliably produce the shape. The shroud’s form required a more advanced tooling concept, along with tighter control over material behavior and trimming.
Tru-Form’s Solution
Rather than force a manual process into their production model, Tru-Form approached the part as an engineering and tooling problem to solve. The team collaborated with an outside tooling partner and developed an articulated tool with moving features that could make the part thermoformable in a more automated environment. That was a major shift from the old drape forming process and gave the customer a path toward more repeatable production.
Tru-Form also worked through the process variables required to make the part perform consistently. The team spent weeks refining the material and process window, including chemical blends, timing, and pressure, until they reached an approved formula. Once that was established, they were able to move from initial engagement to usable production parts in just five months.
Equally important, the new process aligned with how Tru-Form operates as a full-service thermoforming partner, with in-house tooling support, thermoforming, CNC trimming, assembly, and finishing under one roof.
Why This Was a Better Approach
The new solution developed by the Tru-Form team addressed several issues at once.
First, it reduced labor. What had previously required a much more manual process was brought down to a two-person operation, resulting in an estimated 50% labor savings.
Second, it improved consistency. Automated forming and repeatable heating gave the customer more reliable part-to-part results than a hand-shaped process could provide. Tru-Form also brought repeatable trimming into the process through five-axis CNC routing rather than relying on hand trimming.
Third, it improved material usage and overall production efficiency. Because the old drape forming method required a larger sheet for operators to hold and manipulate, material use was less efficient. Tru-Form’s engineered process allowed for optimized sheet blanks and a more controlled production flow, which supported the customer’s pricing goals.
Finally, it turned a fragile, labor-heavy process into a scalable manufacturing solution. That matters in an industry like aerospace, where consistency, throughput, and repeatability are not optional.
Benefits of the Solution
- Estimated 50% labor savings
- More consistent part quality from automated forming
- Repeatable trimming through five-axis CNC equipment
- Better material utilization through optimized sheet blanks
- A faster, more scalable production process
Results For the customer, the value was straightforward. A part that had been difficult, labor-heavy, and inconsistent now had a more repeatable thermoforming process behind it. Tru-Form helped replace an outdated method with an engineered production approach that reduced labor demands, improved consistency, and gave the customer a more practical path forward for future orders. The project even led to an innovation award nomination.
If a difficult part is tying up labor, creating inconsistency, or forcing too much handwork, Tru-Form Plastics can help evaluate a better path. Request a Complimentary Part Evaluation to see whether your current process can be improved through smarter tooling, thermoforming expertise, and a more repeatable production approach.