Custom Die-Cut Aerospace & Defense Materials · For airframe, defense-system & space-hardware engineers

Custom Aerospace, Defense & Space Material Solutions: Insulation, Shielding, Sealing, Thermal & Assembly

Wide reference photo of die-cut materials across aerospace, defense, and space hardware: nacelle and cabin insulation blankets, conductive EMI gaskets on an avionics enclosure, fluorosilicone fuel-zone seals, thermal interface pads on an electronics deck, and bonding tape on an interior panel, illustrating the breadth of the aerospace and defense material vertical

H-O Products converts SOLIMIDE polyimide foam, aerogel insulation, AeroZero polyimide-aerogel film (silicone-PSA films, low-outgassing acrylic grades, graphite-faced spreader films and multilayer fire-barrier laminates), conductive EMI elastomers, Nomex aramid paper, Kapton polyimide film, silicone sponge, fluorosilicone, kSil KSV-series V-0 silicone sponge, PORON microcellular urethane, SSP2390 platinum-cured silicone and low-outgassing silicone sheeting with ASTM E595 screening data, eGRAF graphite, and acrylic foam bonding tapes into die-cut insulation blankets, EMI gaskets, environmental and fuel-zone seals, thermal interface parts, cushioning, and bonding parts for aircraft, defense systems, spacecraft, and the ground equipment that serves them.

Materials are commonly evaluated to program-derived requirements, with MIL and FAR references cited by designation; made to your drawing under an ISO 9001:2015 certified quality management system in Winsted, Connecticut.

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The Aerospace, Defense & Space applications

Where do you need a converted part?

Every sub-application in the Aerospace, Defense & Space vertical, each its own page with the materials, failure modes and converting detail for its job.

Thermal Management · 4 applications
Jet engine nacelle opened for service with die-cut thermal insulation blankets and fire-barrier layers fitted around the engine core and bleed-air ducting Thermal management · 01 Engine Bay & Nacelle Thermal Insulation Die-cut nacelle insulation, fire barriers, and bleed-air duct insulation in SOLIMIDE, aerogel, and inorganic barrier materials. Open page → Aircraft fuselage interior during outfitting with insulation blankets fitted between frames and ECS ducting routed overhead Thermal management · 02 Fuselage, Cabin & ECS Thermal Insulation Fuselage insulation blankets, moisture barriers, thermal spacers, and ECS duct insulation cut to the airframe. Open page → Avionics circuit boards and modules with graphite heat spreaders and thermal interface pads staged for installation Thermal management · 03 Avionics Thermal Management & Interfaces Graphite heat spreaders, gap pads, and thermal isolation gaskets for avionics, radar, and cockpit systems. Open page → Cryogenic propellant lines on a launch vehicle wrapped in flexible aerogel insulation with frost visible on uninsulated fittings Thermal management · 04 Cryogenic & Space Systems Insulation Cryogel Z feedline wraps, spacecraft thermal blankets, and MLI layer materials for launch vehicles and satellites. Open page →
EMI & Electrical · 2 applications
Avionics enclosure cover with a conductive elastomer EMI gasket seated in its machined groove EMI & electrical · 05 EMI Shielding Gaskets for Aerospace & Defense Conductive elastomer gaskets with MIL-DTL-83528 designations per TDS, soft conductive solid, and foil tapes for shielded seams. Open page → Aircraft generator stator with aramid paper slot liners and polyimide film insulation layers staged beside the windings EMI & electrical · 06 Electrical Insulation for Aerospace Power Nomex slot liners, Kapton winding insulation, mica barriers, and laminate supports for aircraft motors, generators, and power systems. Open page →
Sealing · 3 applications
Aircraft cabin door opening with its perimeter seal channel visible and a door gasket being fitted Sealing · 07 Cabin Door & Airframe Sealing Cabin door gaskets, window seals, access panel gaskets, and fuselage seam materials in fire-documented elastomers. Open page → Sealed avionics enclosure with environmental gasket, connector panel seals, and a membrane vent disk arranged beside the housing Sealing · 08 Avionics & Electronics Enclosure Sealing Environmental sealing, pressure venting, RF-transparent radome gaskets, and filtration for avionics enclosures. Open page → Aircraft fuel system access panel with chemical-resistant fluorosilicone gaskets and seals staged for installation Sealing · 09 Fuel, Hydraulic & Chemical-Zone Sealing Fluorosilicone sponge and sheet, FKM, and HNBR gaskets for fuel, hydraulic, de-icing, and oxygen-adjacent systems. Open page →
Fire Safety · 1 application
Aircraft cabin interior panels with fire-smoke-toxicity documented insulation and gasket materials staged during outfitting Fire safety · 10 FST Compliant Materials for Aircraft FAR 25.856 / 25.853-context insulation, fire-rated gaskets, inorganic fire barriers, and heat shields, documented per grade TDS. Open page →
Structure & Motion · 2 applications
Avionics equipment rack with vibration isolation pads and shock mounts fitted between the rack and airframe structure Structure & motion · 11 Vibration, NVH & Shock Isolation Vibration isolation, shock pads, and acoustic damping for avionics racks, cabin interiors, and equipment mounts. Open page → Airframe structural interface with UHMW anti-chafe pads and laminate isolation spacers fitted between dissimilar metal parts Structure & motion · 12 Anti-Chafe, Wear & Structural Interface UHMW anti-chafe pads, PTFE wear protection, laminate spacers, and galvanic isolation strips for airframes. Open page →
Defense & Space · 3 applications
UAV airframe on an assembly bench with its avionics bay open, showing the electronics enclosures and compartment surfaces where cushioning, thermal, and sealing materials install Defense & space · 13 Missile, UAV & Weapons System Materials Shock cushioning, thermal stacks, RF-transparent aperture seals, and lightweight insulation for defense hardware enclosures and airframes. Open page → Satellite bus in a cleanroom integration stand with thermal blanket sections and electronics panels visible where insulation, thermal, and venting materials install Defense & space · 14 Spacecraft & Launch Vehicle Materials Cryogenic insulation kits, MLI layer converting, E595-screened cushioning, and venting for satellites and launch vehicles. Open page → Ruggedized defense electronics enclosures in a ground vehicle equipment rack with gasketed covers and sealed connector panels Defense & space · 15 Defense Electronics, Ground Vehicle & Naval EMI gaskets, ingress sealing, corrosion-documented grades, FST materials, and vetronics thermal parts for platforms. Open page →
Assembly & Process · 2 applications
Aircraft interior panel being fitted with acrylic foam bonding tape strips along its mounting edges on an assembly bench Assembly & process · 16 Aerospace Bonding, Assembly & Adhesive Tape LSE bonding for painted and composite faces, sensor mounting, fixturing tapes, and hot-adjacent hybrid bonds. Open page → Aerospace manufacturing floor with protective film on finished skin panels and kitted foam dunnage trays staged beside the tooling Assembly & process · 17 Ground Support, Manufacturing & MRO Protective films, PTFE process surfaces, tooling pads, and FOD-disciplined kitting dunnage for production and MRO floors. Open page →
Advanced Air Mobility · 1 application
eVTOL and advanced air mobility hardware with battery thermal, fire barrier, EMI and sealing materials Advanced air mobility · 18 eVTOL & Advanced Air Mobility Battery-module graphite heat spreading, cell-to-cell propagation barriers, dielectric TIMs, EMI gaskets, FST cabin insulation and enclosure sealing for eVTOL and AAM programs. Open page →
Related application overviews & capabilities
Lithium battery pack module assembly representing the thermal interface, insulation and fire-barrier applications served by thermal materials. Application overview Thermal Management & Insulation Thermal interface, heat-spreading and high-temperature insulation parts for power and battery hardware. Open overview → elastomer and sponge gaskets staged for an enclosure sealing application. Application overview Engineered Sealing & Gasketing Environmental, EMI and fluid gaskets cut from silicone, EPDM, sponge and foam to the sealing geometry. Open overview → Vehicle suspension and driveline underbody, the vibration environment addressed by isolation, damping and cushioning materials. Application overview NVH, Shock & Vibration Control Engineered foams and isolators that manage controlled force, shock and vibration across the assembly. Open overview → Acrylic foam bonding tape on a release liner, the fastener-replacement bonding family. Application overview Structural Bonding & Fastener Replacement Acrylic foam and transfer tapes that mount, join and bond parts in place of mechanical fasteners. Open overview → dielectric barriers and insulation washers for high-voltage power equipment. Application overview Energy, Power & High-Voltage Dielectric films, papers and rigid laminates that isolate busbars, windings and high-voltage interconnects. Open overview →
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Engineering resources for aerospace, defense & space

Selection guides, failure-mode notes, and project work from H-O engineering, matched to the applications on this page.

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Send a drawing, a system-manual page, or a spec section; partial information is welcome. We typically respond within one business day with a material-family recommendation, the vendor technical data sheet behind it, a prototype lead time, and an honest note on anything that needs a listing holder or a sealant maker rather than a converter.

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Typical response in one business day. Typical prototype lead time is 5–10 business days after drawing review, depending on material availability, tooling, and inspection requirements.

Send a drawing, BOM, or a description of the application and what the part must do, and an engineer responds within one business day with a material-family direction and the matching sub-application page. Program-specific documentation and compliance requirements are reviewed at quote.

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Explore the material library: Foam Materials

Last updated · Reviewed by H-O Products engineering (ISO 9001:2015 certified converter, Winsted, CT).