More Than Molded: High-Level Assembly & Painting at Tru-Form Plastics

Thermoformed parts aren’t complete until they’re ready for real-world use. At Tru-Form Plastics, we go beyond forming and trimming to provide high-level assembly and painting services for some of the most demanding applications in the world. Our work includes lavatory assemblies for luxury airlines, where every detail must meet strict aerospace standards and deliver the premium look and feel expected by top carriers.

Supporting Complex Builds with Integrated Assembly

Many thermoformed parts, especially enclosures, covers, and structural components, require additional work after forming. In projects like aircraft lavatories, our assembly team manages complex builds that involve bonding inserts, installing hardware, and preparing parts for finishing. Keeping these steps in-house maintains tighter control over quality, timelines, and part performance.

Our assembly work often begins with bonding bosses, inserts, and brackets to create fastening points strong enough to withstand repeated use in confined spaces. Many of these assemblies are designed for aircraft interiors, where hardware must be both compact and durable.

We also install hinges, latches, and seals that provide secure access and environmental protection. These details may seem small, but they play a critical role in high-traffic environments where parts are opened and closed hundreds to thousands of times throughout their service life.

In some cases, compliance requires more than structural performance alone. That’s when we apply flame-retardant adhesives that allow assemblies to meet stringent aerospace fire safety standards. Each adhesive is selected and applied to maintain performance without sacrificing fit or appearance.

Finally, subassemblies are carefully prepared for finishing. Whether a part is headed for painting, coating, or hydro dipping, every surface is cleaned, masked, and readied to ensure the final finish adheres properly and meets cosmetic expectations.

These processes allow us to deliver assemblies that balance durability, precision, and appearance in demanding aerospace environments.

Beyond aerospace interiors, the same high-level assembly skills apply across medical, defense, automotive, and electronics programs. Our teams bond inserts into rugged medical housings, install seals and fasteners for automotive enclosures, and prepare electronic components for labeling and surface protection. In every case, customers benefit from an integrated process where forming, assembly, and finishing are carried out under one roof.

Specialized Finishes for Demanding Customers

A clean, flawless finish is critical in premium aircraft interiors. Tru-Form Plastics provides in-house painting, coatings, and hydro dipping to meet cosmetic and functional requirements under the same roof as our forming and assembly teams.

One of our core capabilities is color-matched painting. This allows us to align precisely with branding and cabin standards, ensuring consistency across fleets of aircraft and other high-visibility products. Our team also manages specialty finishes such as hydro dipping, which can deliver unique textures, patterns, or visual effects that elevate the look of finished assemblies.

Surface preparation is another key focus. Before any coating is applied, parts are masked, cleaned, and inspected to maintain adhesion and consistency. This careful prep work helps prevent defects such as overspray or chipping, and it ensures that every finished component meets both cosmetic and functional requirements.

These finishing processes extend well beyond aircraft interiors. Medical device enclosures, branded equipment housings, and automotive covers also depend on consistent, repeatable paint and coating applications. By keeping these steps in-house, Tru-Form reduces variation and creates a dependable supply chain for industries where quality and compliance are critical.

By combining assembly and finishing capabilities, Tru-Form gives customers a single, dependable source for thermoformed parts that are fully assembled, finished, and ready for integration.

Why In-House Assembly & Painting Makes a Difference

When forming, assembly, and finishing happen under one roof, it creates logistical efficiency and leads to better results, delivered faster.

Shorter lead times are a natural outcome because there’s no need to coordinate with multiple outside vendors. Better alignment follows as cosmetic and functional features are managed together from the start. In-house integration also improves part performance, since fit-up, bonding, and paint adhesion are all validated before a product leaves our facility.

The benefits extend to cost and quality as well. Fewer handoffs mean fewer delays, rejections, or freight charges, all of which reduce the total cost of a program. At the same time, a single accountable team manages every step — from prototyping to final shipment — streamlining quality control and simplifying communication.

Customers across aerospace, medical, defense, automotive, and electronics rely on us for parts that are built for purpose, packaged for delivery, and ready to go straight to the next step in their process.

Built for Regulated, High-Performance Applications

From medical housings with bonded inserts to aerospace lavatory panels with hydro dipped finishes, Tru-Form Plastics delivers assemblies that meet both functional and cosmetic requirements. Our experience supporting premium aircraft interiors demonstrates our ability to meet the highest expectations for safety, durability, and appearance in zero-defect environments.

Every project is backed by our AS9100D and ISO 9001:2015 certifications, along with disciplined internal processes for validation, traceability, and repeatability. Customers trust us not only for thermoforming expertise but for complete builds that integrate engineering, assembly, and finishing under one roof.

A Single Source for Thermoformed Parts, Finished and Assembled

We don’t stop at forming. We deliver finished assemblies built to meet cosmetic, functional, and regulatory requirements. Let’s talk about how Tru-Form’s high-level assembly and in-house painting can support your next program.