BREAKING THE MOLD

RCO Aerospace provides aircraft manufacturers with an alternative to the traditional aerospace design and product development approach. Bringing automotive technology, processes, quality, and repeatability to the aircraft industry, RCO is changing the way aircraft seats and interiors are designed, built, and installed. Many of our projects are joint development programs where we design and produce a product unique to each customer’s requirements.

AEROSPACE SERVICES

Design & Engineer

Over 300 engineers and designers experienced in plastic, metal, and composite product design.

Our team has designed 4 families, with 25 different model numbers, of TSOA seats and divans that are in service today.

Two concept aerospace seats for the business jet seating market. Interior of a business jet appointed in leather.
Interior of a business jet appointed in leather.

Over 300 engineers and designers experienced in plastic, metal, and composite product design.

Our team has designed 4 families, with 25 different model numbers, of TSOA seats and divans that are in service today.

Prototyping & Mockups

Using RCO’s suite of capabilities we are able to provide our customers with full scale interior and exterior

mockups utilizing the latest technology and material types. We have dedicated well over 7,000 sq ft of build space and can flex space to accommodate private build areas for classified programs.

A mocked up airplane fuselage sits in RCO's shop. A full size airpane fuselage mocked up by RCO.
A mocked up airplane fuselage sits in RCO's shop.

Using RCO’s suite of capabilities we are able to provide our customers with full scale interior and exterior

mockups utilizing the latest technology and material types. We have dedicated well over 7,000 sq ft of build space and can flex space to accommodate private build areas for classified programs.

Certification & Testing

RCO Certification Dept is well versed in all facets of FAA seat and divan TSO approval processes; including static, dynamic, and flammability test plans.

Staff DMIR, along with multiple supporting inspectors, support FAA conformities and FAIs.

We perform durability testing, static testing, fatigue testing, and environmental chamber testing in our  25,000 sq ft A2LA accredited mechanical test lab.

All of our dynamic testing takes place in FAA approved labs like NIAR at WSU.

 

 

RCO's Robostand product tests an aerospace seat. RCO's Robostand product tests an aerospace seat.
RCO's Robostand product tests an aerospace seat.

RCO Certification Dept is well versed in all facets of FAA seat and divan TSO approval processes; including static, dynamic, and flammability test plans.

Staff DMIR, along with multiple supporting inspectors, support FAA conformities and FAIs.

We perform durability testing, static testing, fatigue testing, and environmental chamber testing in our  25,000 sq ft A2LA accredited mechanical test lab.

All of our dynamic testing takes place in FAA approved labs like NIAR at WSU.

 

 

Production and Repair

RCO Aerospace has a dedicated seat manufacturing facility with the expertise and capabilities to take on any program. We produce over 80 percent of the seat components in house for

our production seat programs. Our facility also touts an EASA approved FAA Certified 145 repair station with specialization in

seat and component repairs.

RCO Aerospace's manufacturing facility. A worker at RCO aerospace assembles a seat in our manufacturing facility.
RCO Aerospace's manufacturing facility.

RCO Aerospace has a dedicated seat manufacturing facility with the expertise and capabilities to take on any program. We produce over 80 percent of the seat components in house for

our production seat programs. Our facility also touts an EASA approved FAA Certified 145 repair station with specialization in

seat and component repairs.

 AEROSPACE

CAPABILITIES

Composites

  • STRUCTURAL
  • NON STRUCTURAL
  • SHORT CYCLE TIME
  • SMC CHOPPED CARBON FIBER
  • REDUCED OR ELIMINATED POST PROCESSING
  • PRE-PREG STRUCTURAL COMPONENTS
  • VARYING PART THICKNESS
  • COMPLEX PART SHAPES
  • INTEGRATED FASTENERS AND STIFFENERS
  • STRUCTURAL INTEGRITY
A concept aerospace seat with carbon fiber and leather. A carbon fiber footrest assembly for an aerospace seat.
A concept aerospace seat with carbon fiber and leather.
  • STRUCTURAL
  • NON STRUCTURAL
  • SHORT CYCLE TIME
  • SMC CHOPPED CARBON FIBER
  • REDUCED OR ELIMINATED POST PROCESSING
  • PRE-PREG STRUCTURAL COMPONENTS
  • VARYING PART THICKNESS
  • COMPLEX PART SHAPES
  • INTEGRATED FASTENERS AND STIFFENERS
  • STRUCTURAL INTEGRITY

Foam Components

After 30 years of pouring foam for our automotive customers we are now perfecting this process for the aerospace industry.

We can pour polyurethane directly into a mold and have a finished pad in less than 10 minutes.

If CAD data is not available and turn around time is tight, we can hand shape foam pads to any contour or hardness.

If CAD data is available we can use our CNC machines to cut multiple shapes of varying hardness.

Foam blocks used for aerospace seating. A worker operates a molded foam machine at RCO engineering.
A worker operates a molded foam machine at RCO engineering.

After 30 years of pouring foam for our automotive customers we are now perfecting this process for the aerospace industry.

We can pour polyurethane directly into a mold and have a finished pad in less than 10 minutes.

If CAD data is not available and turn around time is tight, we can hand shape foam pads to any contour or hardness.

If CAD data is available we can use our CNC machines to cut multiple shapes of varying hardness.

Metal Components

RCO has extensive metal working capabilities to support the aerospace industry. Our CNC department houses milling machines, ranging from 3 axis to 5 axis and are dedicated to machining aluminum components for structural and aesthetic functions in aerospace interiors. In addition, we design and build our own dies, to stamp out lightweight aluminum and high strength steel components for seat structures, and other interior assemblies.

 

Machined aluminum components for an aerospace seat. A worker assembles seats in RCO aerospaces production manufacturing facility.
A worker assembles seats in RCO aerospaces production manufacturing facility.

RCO has extensive metal working capabilities to support the aerospace industry. Our CNC department houses milling machines, ranging from 3 axis to 5 axis and are dedicated to machining aluminum components for structural and aesthetic functions in aerospace interiors. In addition, we design and build our own dies, to stamp out lightweight aluminum and high strength steel components for seat structures, and other interior assemblies.

 

Plastic Components

We've been producing rapid prototype parts for the automotive industry since 1990. Using our FDM technology we can produce exact copies of your CAD file overnight, in a variety of materials. Once a part is made we build silicon molds which enable us to hand pour additional copies at a fraction of the cost. From the FDM we can also build small to large injection molds that can produce well over 20,000 parts.

A plastic injection molded component. A fused deposition modeled (FDM) plastic component rapid prototyped in RCO's facility.
A fused deposition modeled (FDM) plastic component rapid prototyped in RCO's facility.

We've been producing rapid prototype parts for the automotive industry since 1990. Using our FDM technology we can produce exact copies of your CAD file overnight, in a variety of materials. Once a part is made we build silicon molds which enable us to hand pour additional copies at a fraction of the cost. From the FDM we can also build small to large injection molds that can produce well over 20,000 parts.

EXISTING TSOS

Electro Hydraulic Powered Single

Electro Hydraulic Powered Single

Electrical Assist Manual Single

A leather appointed aerospace seat for a business jet.

Double Configuration

A double seat configuration for a business jet.

Divan

A leather appointed aerospace Divan.
A high end business jet aerospace seat.
A leather appointed aerospace seat for a business jet.
A double seat configuration for a business jet.
A leather appointed aerospace Divan.
A high end business jet aerospace seat.
A leather appointed aerospace seat for a business jet.
A double seat configuration for a business jet.
A leather appointed aerospace Divan.

CUSTOM DIVANS

A custom L shaped divan for a business jet. A custom L shaped divan for a business jet.
L-shaped Divan

Specifically designed for large business jet installations.
A custom divan for a business jet. checkered-divan329x239
Certification

Certification can be completed with inflatable shoulder restraints and leg flail.
Twin bed

Power or manual option available to berth twin bed.
Storage Options

Lower compartment available with optional drawers, doors, or storage boxes.

 Our Place in the Aerospace Engineering Industry

Historically, leading jet manufacturing brands were limited to just a few seat manufacturers. When they sought new, out of the box aircraft seat manufacturers, they found RCO Aerospace Products.

Our reputation in the automotive industry and our expertise with lightweight materials uniquely positioned us to meet and exceed the aerospace industry’s stringent aesthetic, functional and design requirements.

 

Today, we’re proud to be a trusted partner for aerospace design, engineering, testing and manufacturing. You’ll find RCO created seating high above the clouds in the exceptionally comfortable foam products of commercial aircraft, to the extremely custom VIP seating of business jets.

AS9100, ISO9001, ISO17025, ISO14001, FAA CERTIFIED 145 REPAIR STATION #2RCR028C

RCO Aerospace Official