Products
Sewn, Sealed, & Thermoformed Aviation Products for OEMs
Since 1947, Polo has earned a reputation as a trusted leader in custom manufacturing, serving the aviation industry with expertise in Sewing, RF sealing, and Thermoforming. We understand the unique challenges you face, and we’re committed to helping you deliver quality manufacturing solutions that meet your needs.
Precision Manufacturing for the Aviation Industry
The aviation industry requires a level of reliability that we don’t often see in other industries. Whether it’s for seat covers, protective cabin covers, fire-resistant interior covers, parachutes, and much more, Polo manufactures products that are built to last. We specialize in thermoforming—a process that creates lightweight yet durable parts by heating and shaping materials like nylons, polyester, PVC, and fire-retardant fabrics. This is ideal for aviation components that need to be both strong and lightweight.
Our sewing and sealing services ensure that every part we create goes through a quality testing lab that meets the requirements of the aviation industry. We take pride in producing custom solutions tailored to your needs, whether you’re looking for simple sewn goods or complex, specialized parts. Our product development team will work closely with you to ensure the product you bring to market meets all functional, safety, and performance requirements.
We offer manufacturing solutions for large commercial airlines, military aircraft, and privately owned aircraft companies. Some examples of work within our capabilities are listed below:
- Seating
- Form Pouches
- Insulation Blankets
- Service Covers
- Protective Intake Covers for Large Aircraft
- Soundproof Blanketing
- Protective Covers
Polo is always looking for new business, with an expansion of our 3rd faciality in Topeka, Kansas underway for 2025-2026 we will be adding thousands of square feet for sewing machines, tooling for thermoforming and RF welding, allowing us to scale effectively. We embrace taking a project from concept to creation, and we know how to get products out the door.
The Quality Experts
When you choose Polo, you’re selecting a partner with an unwavering commitment to quality. We hold ISO 9001:2015, ISO 13485:2016, and FDA QSR 21 CFR Part 820 certifications, all of which reflect our dedication to maintaining the highest manufacturing standards.
In addition to our ISO certifications, Polo is also a Berry Compliant supplier, ensuring that the materials we use in our aviation products meet textile requirements set by the U.S. government. With long-term partnerships with the U.S. Armed Forces, our commitment to quality extends throughout the production process, from design to delivery, ensuring that every part we make is up to our military’s standard.
Supporting U.S. Manufacturing
We’re proud to be a U.S.-based manufacturer. As global supply chains face uncertainty, more companies are recognizing the value of domestic manufacturing. By sourcing parts from Polo, you gain faster turnaround times, better quality control, and a more reliable supply chain. With tariffs on imported goods continuing to rise, we provide a valuable solution that helps keep your production running smoothly while supporting American-made goods.
Custom Solutions for Your Aviation Needs
Every aviation project is unique, which is why we don’t believe in a one-size-fits-all approach. Whether you’re producing enclosures, envelopes for fuselages and wings, or specialized protective covers, we use a Phase Gate process to DFM (Design for Manufacturability). The process involved in design for manufacturing includes five major components: Process, Design, Material, Environment, and Testing/Compliance. DFM should preferably occur early on in the design phase, long before production starts. Additionally, effective DFM will include all parties with a stake in the project, including designers, engineers, mold builders, contract manufacturers, and material suppliers. In order to properly evaluate and challenge the design, we follow this Phase Gate process, a four-step process that has proven successful time and time again. The four steps are:
- Research
- Development
- Production Planning
- First Production
Why Choose Polo as Your Preferred Supplier?
For 78 years, Polo has been a trusted manufacturing partner for the industries we serve. We understand the critical need for quality, custom-made components that meet performance and safety standards. Our expertise in thermoforming, sewing, and sealing gives us the flexibility to meet the demands of our customers’ array of different projects.
With certifications, a commitment to U.S. manufacturing, and a proven track record of delivering high-volume custom solutions on time, Polo is the right partner for your aviation manufacturing needs. We’re not just a supplier; we’re an extension of your team, dedicated to guiding success.
Ready to get started? Contact Polo Custom Products today to learn how we can help bring your aviation projects to life with precision and reliability.
