Defense Aeronautics, Civil Aeronautics and Space are our main focus core businesses.

PLYFORM is an Italian company specializing in the development and production of high-performance composite components.

Born from a combination of passion, innovation and technical expertise, the company has built a solid reputation over time as a reliable partner for the Aerospace, Automotive and other industrial sectors.

Aircraft

While the world of helicopters represented the origin and heart of our history, the aeronautical sector marked a path of growth and international consolidation for PLYFORM.

Over the years, the company has expanded its scope by collaborating with leading commercial and military aircraft manufacturers, bringing the know-how gained in the helicopter industry to new technological and production challenges.

Today, aeronautics represents a strategic area for PLYFORM, where innovation, precision and certified processes translate into complex, high-performance components:

  • composite panels and fairings
  • highly reliable structural and semi-structural parts
  • integrated assemblies and sub-assemblies, ready for final installation.

Our contribution to the aircraft sector is based on our ability to combine certified quality, advanced technologies and production flexibility, supporting our customers in the development of new generation programs.

Helicopters

The helicopter sector has always been at the heart of our history and our activities.

Since its inception, the company has built up its know-how by working closely with leading international manufacturers, becoming a key partner in the production of composite components for helicopters.

This sector still represents our main field of activity today, where technical expertise, certified processes and advanced technologies translate into products of excellence, capable of guaranteeing safety, lightness and reliability.

Our achievements include:

  • high-tech structural components
  • high-performance composite fairings and panels
  • lightweight and functional interior design elements
  • complex assemblies of primary structures, with high quality standards.

The experience gained in the helicopter sector has shaped PLYFORM’s identity, guiding its evolution and laying solid foundations for growth in other fields of application.

Automotive & Motorsport

In addition to the aeronautical sector, PLYFORM puts its expertise at the service of the automotive and motorsport worlds, where performance, lightness and design are fundamental.

Thanks to the technologies developed in the aeronautical field, we manufacture composite components that combine mechanical strength, precision and weight reduction, ensuring high performance both on the road and on the track.

Our capabilities include:

  • structural and semi-structural composite parts
  • high-tech aesthetic and functional components
  • prototypes and small series for high-performance vehicles
  • customized solutions for motorsport teams and manufacturers.

PLYFORM supports its partners at every stage, from design to production, with the same attention to certified quality that distinguishes its activities in the aeronautical sector.

Engineering & Tooling

PLYFORM is not just about production: our added value comes from the integration of engineering and manufacturing.

Thanks to a team of highly qualified engineers and technicians, we are able to support our customers from the early stages of development, transforming ideas into concrete solutions.

Our engineering expertise includes:

  • design and development of composite components
  • structural analysis and lay-up optimisation
  • co-design and technical support throughout the product life cycle.

At the same time, the Tooling department manufactures equipment and moulds in-house, ensuring maximum precision and fast turnaround times:

  • construction of moulds for lamination and autoclave
  • positioning and control equipment
  • internal tool maintenance and management.

This integrated approach allows us to offer flexibility, speed and certified quality, strengthening PLYFORM’s role as a comprehensive and reliable partner.

Research & Development / NPI

Innovation is an integral part of PLYFORM’s DNA.

Through constant research and development, we explore new technologies, materials and processes to anticipate market needs and offer increasingly high-performance and sustainable solutions.

Our R&D department works closely with universities, research centers and industrial partners to develop:

  • new materials and hybrid systems
  • innovative and more sustainable production processes
  • advanced quality control and inspection techniques.

Alongside R&D, the NPI (New Product Introduction) process is a strategic pillar:

  • complete cycle management, from prototyping to mass production
  • process validation through testing and certification
  • customer support in the development of new programs and platforms.

This combination of research and industrial capabilities allows us to transform ideas into real products, ensuring innovation, reliability and competitive time-to-market.

CAPABILITIES

Assembly

Description:

  • N°2 Oven 6x4m up to 80°C
  • N°1 Oven 4,5x2m up to 195°C

Description:

  • 3.000mq Lean Philosopy
  • EMA
  • N°3 Rework Rooms 6x4m

Description:

  • 18m x 4m  divided in 3 rooms of 6m each
  • N°1 Sandblasting Machine 2x1m
  • N°1 Sandblasting Machine 1x1m

Description:

  • 90m2 up to 1500 STD STOCK

Composite

Description:

  • 2 Automated Feeding with rolls up to 2m, prepreg & honeycomb

Description:

  • 2 Laser Projection Station with rools up to 2, prepreg & honeycomb
  • 8 Laser Projection Station ± 0,25mm tolerance on 54m≤, SL Laser

Description:

  • 1 Clean room 260mq ISO Class 8 according to ISO 14644-1
  • 1 Clean room ~275mq ISO Class 8 according to ISO 14644-1
  • 1 Clean room ~117mq ISO Class 8 according to ISO 14644-1
  • 1 Clean room ~300mq ISO Class 8 according to ISO 14644-1

Description:

  • N. 1 Autoclave 10m x Ø4,5 up to 250° 10bar
  • N. 1 Autoclave 6m x Ø02,6 up to 250° 10bar
  • N. 1 Autoclave 5,2m x Ø 2,1 up to 200° 10bar
  • N. 1 Autoclave 4m x Ø 1,5 up to 200° 10bar
  • N. 1 Autoclave 6m x Ø 02,5 up to 200° 10bar

Description:

  • 1 3D Printing Machine
  • FDM 914mmx610x914 mm

Description:

  • N. 1 Heated Press – 270 tons, 0.7mX0,7m FDM

Description:

  • 1 CNC – Saxis • 6.0mX2.7mX1.7m, Rambaudi
  • 1 CNC – Saxis • 2.6mX1.5mX1.2m, CMS

Quality

Description:

  • 1 T.AU.R.U.S im.4 itt immersion tank 4×0,6×0,8m
  • 1 T.AU.R.U.S 4 tt water column system 4,5×1,85x2m
  • 1 T.AU.R.U.S 4 tt water column system 3×1,8x2m
  • 1 1CH Ultrasonic Inspection Phased Array 18-128 modules
  • 1 1CH Ultrasonic Inspection Poulsecho

Description:

  • Static Mechanical Tests
  • Hplc
  • Dsc
  • Dma
  • Muffle Furnace For Calcination
  • Resin Content
  • Stereoscope

Description:

  • 1 CMM Coords Ares
  • 1 CMM Coords 3 3,5x2m

Headquarter Varallo Pombia

Production Plant San Gillio