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Our deep understanding of plastics and modern thermoforming techniques, combined with our latest technology equipment, won our contract for manufacturing retrofit windows for the helicopter pictured here. Built in the 1950s, this historic aircraft, the U.S. Army’s first turbine-powered helicopter, was being restored by the manufacturer for display in the New England Air Museum.

There were many challenging aspects to this project. Specifications called for the 60” x 64” x 33” pilot and co-pilot windows to be optically clear polycarbonate with a uniform thickness of 0.150”, accurate to within ±.015”. The complex geometry, clarity requirement and strict budgetary controls required meticulous planning on our part. We gave thoughtful consideration to tooling material and design and maintained tight gauging control over the thermoforming and trim processes to ensure tolerances were met. Extreme care and preparation went into readying the components for safe shipment to the museum in Connecticut.

There is no substitute for knowledge and experience when it comes to projects of this complexity. We have the talent to manufacture unique parts with care and precision all within reasonable time frames and at reasonable cost. To learn more about this project, or how our precision thermoforming services can benefit your application contact us today.

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Thermoforming of a Clear Polycarbonate Helicopter Window Project Highlights

Product Description

Pilot and Co-Pilot window for a Sikorsky S-59 helicopter in the New England Air Museum.

Capabilities Applied/Processes

CNC Machining
Extreme care and preparation was required to prepare the shipment to its destination

Equipment Used to Manufacture Part

Large Rotary Thermoformer

Overall Part Dimensions

60.0” wide x 64.0” long x 33.0” high

Tightest Tolerances

Absolute uniform thickness control was required throughout the part of +/- 0.015”

Material Used

Clear Polycarbonate
Thickness: 0.150”

Material Finish

Window clear finish

In process testing/inspection performed

Gauge and trim control in addition to careful preparation of the products for shipment

Industry for Use

Air Museum Industry


Retro-fit two Sikorsky helicopters

Delivery/Turnaround Time

Eight (8) weeks on tooling and an additional two (2) on product

Delivery Location


Standards Met

Customer Specifications, 2D CAD Drawing

Product Name

Helicopter Window