Custom Panels

New metal panel design is a lengthy iterative process to ensure the client has exactly what they want within the bounds of possibility.

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We start with a discussion about the mission, the aircraft, preferred ergonomics and avionics selections.

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Once a design is settled on we print a full scale representation on paper and send to the client, optionally we can also prepare an acrylic sheet representation.

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Final changes are made, and if required new paper or acrylic versions are prepared.

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Once a design is settled on, we use a CNC Router to cut the 6061-T6 sheeting. Sheet thickness will depend on the aircraft, but a minimum of 0.080" is recommended. 

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The new panel is then lightly deburred, and prepped with PreKote (modern non lethal Alodine). This is not for corrosion resistance (6061 is naturally so) but for maximum powder coat adhesion.

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The panel is then powder coated in the clients preferred colour, and baked. Powder coating produces a much physically and chemically tougher surface than painting.

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Once baked and cooled, the panel is then covered in vinyl stencil and text and graphics are laser etched with a slight erosion of the base metal to create a depression for paint.

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The text and graphics are then airbrushed on through the laser cut mask in the clients preferred colours.