Plastic Injection Molding for Defense Industries

Precision manufacturing and metal replacement
  • High performance plastic
  • Plastics up to 50% lighter than metals
  • Flexible, custom designs

The use of machined and molded plastic components has revolutionized the defense industry. Thermoplastic polymers are lighter and more resistant to corrosion than metals and are also more durable than glass. Additionally, plastic components provide electrical insulation, and some types have almost zero conductivity.

Benefits of plastic in the defense industry

Plastics are used in defense applications for their high-performance characteristics, enduring extreme temperatures without changing shape. Thermoplastics are also chemical-resistant, weather-resistant, and flame-resistant suitable for defense applications.

Complex geometries – Plastic injection molding is exact and customizable; it can be used to create a wide variety aircraft parts and components with unique shapes and fine features.

Tight tolerances – Plastics can be molded, machined, and finished to the extremely tight tolerances required by the defense industries.

Repeatability – Using advanced injection molding machines, we can produce a large number of uniform and precise military-grade products


PEEK and Torlon components

PEEK (Polyetheretherketone) and Torlon (PAI) are the two most commonly used ultra engineering plastics in the defense industry.

  • PEEK is a thermoplastic polymer that often is formed into valve seats and pump gears because of its low flammability, creep resistance, and ability to endure high water pressure and temperatures exceeding 400°F.
  • Torlon is often a replacement for metal due to its excellent creep resistance, low thermal expansion, and heat-resistance up to 500°F. It is also one of the highest performing melt-processable thermoplastic polymers available.

Thermoplastic in defense sectors

Machined and molded plastics are heavily used in manufacturing military components for various defense applications, including:

  • Aerospace: Aircraft, spacecraft, missiles, air defense systems.
  • Military Vehicles: Tanks, humvees, armored personnel carriers, other land-based combat vehicles.
  • Naval Systems: Submarines, surface ships, naval aircraft carriers.
  • Electronics and Communications: Electronic systems, sensors, radars, communication equipment, electronic warfare systems.
  • Defense Services and Logistics: The Department of Defense recognizes the importance of thermoplastics in support services, logistics, maintenance, training, and consultancy.
  • Research and Development (R&D):Injection molding and machining is heavily used in the research and development of new military technologies.
  • Defense Contractors: Private defense contractors use molded plastics in equipment and system manufacturing.
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