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High robot density & full automation
Comprehensive quality documentation
75% lower carbon footprint compared to the industry average
Clamping force up to 900 tonnes
Shot weight up to approx. 1.5 kg
Trusted for over 50 years
Why aerospace companies rely on VARIOPLAST
Where absolute safety is paramount, uncompromising standards are crucial: materials must be qualified and approved for their specific application, processes must be validatable, and every batch must be fully documented. Plastic components for the aerospace industry must also meet the highest standards in terms of weight optimisation (lightweight construction), temperature resistance and reproducibility. VARIOPLAST meets these requirements – as a certified, owner-managed manufacturer with over five decades of experience in precision manufacturing.
01 – Fully automated production
Our highly automated manufacturing processes, utilising state-of-the-art robotics, ensure the highest precision, consistent quality and perfect reproducibility – from small-batch production to large-scale manufacturing. Fully automated in-line processes enable cost-effective production with minimal scrap rates, even for smaller batch sizes.
02 – Comprehensive quality documentation
Every component leaves our factory with full quality documentation. All manufacturing processes are documented, traceable and can be audited at any time – an essential requirement for plastic components in the aerospace industry.
03 – Certified Process Reliability
VARIOPLAST is certified to IATF 16949, DIN EN ISO 9001 and DIN EN ISO 14001:2015. These certifications demonstrate documented process reliability, systematic quality management and an environmental management system that complies with the relevant standards. For project-specific requirements in the aerospace sector, we coordinate all additional quality and documentation standards individually with our customers.
04 – In-house toolmaking
Short lead times and design support right from the product development stage – thanks to our in-house toolmaking facility at our production site in Germany. Project-specific modifications and tool adjustments are implemented quickly without relying on external suppliers.
Range of services
Our services for the aerospace industry
From the initial idea to the finished, packaged product – VARIOPLAST is your comprehensive one-stop partner throughout the entire value chain. Every stage of the process – from development and toolmaking to packaging – is carried out in-house and under a single, unified quality management system.
Injection moulding processes
- 1K/2K injection moulding of simple to highly complex geometries
- Multi-component injection moulding for functionally integrated, weight-optimised components
- Insert moulding for metal-plastic assemblies (combining strength with lightweight construction)
Surface finishing & special techniques
- Laser engraving for markings, batch numbers and QR codes to ensure full traceability
- Printing, coating, PVD metallisation (Cr6-free) to specification
- Laser cutting, 3D foaming, ultrasonic welding, CO₂ pre-cleaning
- ESD-compliant manufacturing for sensitive avionics and electronic components
Toolmaking & Development
- In-house toolmaking for fast turnaround times and maximum flexibility
- Design support right from the product development stage
- Rapid tooling for prototypes and pre-production runs
- Dedicated tool procurement team in Hong Kong for cost-optimised tools
Product-specific packaging
- Product-specific packaging solutions made from thermoformed trays
- VARIOBOXX® reusable packaging made from recycled materials
Areas of application
Components & Applications for the Aerospace Industry
VARIOPLAST manufactures plastic components for a wide range of applications in the aerospace industry. The components produced must meet the highest standards in terms of weight optimisation (lightweight construction), temperature resistance, precision and reproducibility. Typical examples of applications:
- Enclosures and covers with insulation and safety functions for avionics and cockpit systems
- Brackets, clips and cable management components for securing cable harnesses in aircraft construction
- Display and frame housings for cockpit and passenger information systems
- Handles and control elements with increased requirements for haptics and robustness
- Control knobs and switches for control panels and control systems
- Seat components and lightweight structural parts for passenger cabins
- Hinges and moving elements for flaps and covers
Quality Management & Standards
Quality Assurance & Standards
In the aerospace industry, quality is the top priority – it must be measurable, standardised and verifiable at all times. VARIOPLAST has a comprehensive quality management system that meets all key requirements for plastic components in the aerospace industry:
3D scanner-based measurement system for precise initial sample inspection and ongoing production monitoring
All processes are documented, traceable and auditable
Active support with PPAP documentation, FMEA and initial sample reports
Support available on request from the tool design stage onwards
Complete batch documentation and traceability
For project-specific documentation and requirements within the aerospace sector, we work closely with our customers and tailor all relevant quality and documentation standards to their specific needs.
- IATF 16949 DE
- IATF 16949 EN
- DIN EN ISO 9001 DE
- DIN EN ISO 9001 EN
- DIN EN ISO 14001:2015 DE
- DIN EN ISO 14001:2015 EN
- PPAP
- FMEA
- First-article inspection
Production & Sustainability
Sustainable manufacturing for the aerospace industry
In the aerospace industry, sustainability and quality go hand in hand. VARIOPLAST is consistently reducing its environmental footprint – as a partner that actively supports its customers’ sustainability goals. VARIOPLAST has demonstrably achieved CO₂ emissions that are 75% lower than the industry average: this is made possible by fully automated processes based on lean principles, its own photovoltaic system (600+ kWp, Active Building Standard) and closed material cycles.
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a smaller ecological footprint than the industry average
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Photovoltaic output
(Active Building Standard)
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of manufacturing experience in Germany
Fully automated production reduces waste and cuts energy and resource consumption
Production based on lean principles: eliminating waste, efficient use of resources and continuous optimisation throughout the entire value chain
Environmentally friendly PVD metallisation (Cr6-free) as an alternative to electroplating processes
Active Building Standard: photovoltaic system (600+ kWp), geothermal energy and heat recovery
VARIOBOXX® reusable packaging made from recycled materials
Single-stream waste disposal and closed-loop material cycles
Frequently asked questions about plastic injection moulding in the aerospace industry
VARIOPLAST offers a comprehensive range of services from a single source: development consultancy, in-house toolmaking, fully and semi-automated injection moulding, surface finishing (including PVD metallisation, painting and laser engraving), joining and cutting techniques, assembly and product-specific packaging. The entire value chain is subject to a uniform quality management system in accordance with IATF 16949 and ISO 9001 – for simple parts as well as highly complex geometries with tight tolerance requirements.
Made in Germany: VARIOPLAST is an owner-managed family business and has been manufacturing exclusively in Germany, in Baden-Württemberg, for over 50 years. The branch in Hong Kong is solely responsible for tool procurement and has no influence on production or quality assurance.
VARIOPLAST processes a wide range of engineering plastics and high-performance polymers suitable for use in aerospace engineering – including PEEK (polyetheretherketone, which offers exceptional resistance to high temperatures and chemicals), PP, PE, ABS, PC and other high-performance polymers in fibre-reinforced or flame-retardant versions. The choice of material is always project-specific and made in close consultation with the customer.
Yes. In addition to pure injection-moulded parts, VARIOPLAST also supplies ready-to-install assemblies – complete with assembly, marking (laser engraving for traceability), surface finishing (e.g. PVD coating, painting, printing), packaging and full quality documentation. As a one-stop partner, VARIOPLAST covers the entire value chain, from injection-moulded components to production parts ready for dispatch.
VARIOPLAST is certified to IATF 16949, DIN EN ISO 9001 and DIN EN ISO 14001:2015. For project-specific requirements in the aerospace sector – including industry-specific quality and documentation requirements – we work closely with our customers and tailor all relevant standards to their individual needs. Please feel free to contact us.
Fully and semi-automated processes ensure optimum quality with excellent reproducibility and shorter production times – thereby significantly reducing the overall cost per component. At the same time, in-house toolmaking ensures quick turnaround times for tool modifications and minimises reliance on external suppliers.
VARIOPLAST is equipped to handle both small and medium-sized production runs as well as large-scale production. VARIOPLAST has injection moulding machines with a clamping force of up to 900 tonnes and a shot weight of up to approximately 1.5 kg. Thanks to highly automated in-line processes, even smaller batch sizes can be produced cost-effectively. Please contact us for a bespoke quote.
VARIOPLAST achieves a 75% smaller environmental footprint than the industry average – thanks to fully automated processes based on lean principles with minimal waste, a photovoltaic system with over 600 kWp (Active Building Standard), geothermal energy, heat recovery, environmentally friendly PVD metallisation (Cr6-free) and single-material waste disposal.
VARIOPLAST is your partner from concept to production part
VARIOPLAST is not just a manufacturer – VARIOPLAST is a development partner. This owner-managed family business, based in Germany, supports customers in the aerospace sector from the initial design concept through to tooling and the delivery of a packaged, fully documented finished part. The focus is on reliability, continuity and a partnership that extends far beyond the first order.
VARIOPLAST combines over 50 years of production experience in Germany, a fully integrated one-stop service, lean production and a certified quality management system (IATF 16949, ISO 9001, ISO 14001:2015) – the foundation for reliable supply chains in the aerospace industry.
Our contacts for aerospace engineering
Varioplast GmbH
Varioplast Konrad Däbritz GmbH
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Varioplast Co. Limited (HK)
Varioplast Holding GmbH