Driving Strategic Impact for Critical Industries

This key expansion underscores our commitment to driving innovation and improving the quality of advanced materials to support aerospace, defense, space energy, and other key industries. The advancement of new and cutting-edge materials and processes has been pivotal in driving progress in these industries while improving products’ power, speed, range, duration, shielding, and thermal protection.

We are committed to serving as a strategic partner for organizations seeking high performance, U.S.-based manufacturing that meets the rigorous demands of these critical industries and product requirements—including control over the supply chain, compliance with federal regulations, and affordable high-rate production.

For our customers, this expansion means you can expect greater product reliability, superior quality, enhanced value as a vertically integrated supplier, and increased speed and flexibility to meet rapidly evolving mission needs.

Full Lifecycle Manufacturing—All Under One Roof

The newly expanded facility allows us to provide end-to-end (E2E) manufacturing support—from the initial design to prototyping, manufacturing, testing, quality, supply chain, and assembly. Plasma has focused on bringing most capabilities in-house and within a specific supply chain close to our facilities to better increase efficiency, communication and reduce overall lead times.

By producing materials end-to-end in our facilities, we can now:

• Deliver on shorter timelines – There’s no need to coordinate between multiple vendors, and design changes can be implemented quickly by the production team.
• Improve quality – A single quality management system reduces errors when the same facility handles the entire production process.
• Foster innovation – Our design and production teams collaborate seamlessly to ensure new ideas are viable.
• Streamline communication – One partner oversees the full production process, eliminating multiple points of contact.

Since manufacturing for extreme environments requires the highest reliability and quality standards with often many unknowns, full lifecycle support minimizes the risk of failure by streamlining processes through one vendor. This means faster iterations, easier customization, fewer delays due to shipping, and reduced costs.

Enhanced Capacity for Specialty Manufacturing

The expanded facility also makes it possible to house more specialized, large-scale equipment required for advanced material processing—including more El-Form™ units, plasma spray chambers, walled areas, machining (including more EDM’s and a 5-axis), a new clean room, increased quality areas, a generator for 24/7 operations, and more. Plasma has doubled its work force, facilities, and capabilities over the last three years and now has 80,000 square feet and 80+ personnel to support our customers while we plan to continue to grow.

This added capacity allows for larger and more complex builds, that require multistage assembly and/or processes. Some products move through a series of dedicated areas for assembly, which must be positioned with safety requirements in mind. Heavy, oversized components also require extra clearance for lifting cranes and transport equipment which we have designed into our facilities and allow for higher rates of these larger products.

In extreme environments, even the smallest flaw can lead to mission failure—making rigorous quality control essential. The expanded capacity means we can integrate enhanced inspection technologies and conduct advanced testing that simulates the exact pressures, temperatures, and conditions your materials and products will face. We have increased testing capabilities, including arc-jet and sub-sonic combustion flame testing.

Advanced Equipment and Technology

Our latest investments include:

• El-Form® Electro-Deposition – A versatile process producing extremely pure, dense, and ductile refractory and platinum group metal structures, coatings, and catalysts or foams. We increased dedicated floor space and equipment.
• 5-Axis Machining – A high-precision CNC process that operates along five different axes simultaneously for complex geometries.
• EDM Machines – Electrical discharge machining for shaping metals with extreme accuracy using controlled electrical sparks. Four of these machines have rotary capability.
• Plasma Spray Cells – Allow for high-rate production in enclosed and dedicated spaces, thus increasing one of our core competencies to provide TBC, EBC, and other specialty coatings, plasma-formed components, shielding, and thermal protection solutions.