Aerospace Protection Foams

For over 25 years, Coplan have supported the aerospace industry in the design, manufacture and supply of custom protection foam products for use during aircraft manufacture, maintenance and transit.

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Heavy-duty foam solutions that safeguard valuable aerospace components

Coplan work with aerospace clients developing custom solutions to protect parts and components during manufacturing and maintenance processes.

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We have designed and manufactured over 30 specialist protection foam products used by customers across the globe.

Our team can interpret specific client requests and produce solutions based on our own design standards or on strict client drawings and specifications. Coplan solutions save clients money, protecting complex, intricate parts and high-value components from damage and Engineers and Employees from Health & Safety concerns.

With key expertise in bespoke solution development, CAD / CAM and CNC design, machining, prototyping and manufacturing, we can offer protective solutions using a range of materials including: Low and high density foam (LD / HD), rubber, nylons, polyethylene, polyester plywood and metals such as stainless steel and aluminium.

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Heamar

I have used Coplan on a number of occasions and they have always been very helpful. The foams they have provided always fit everything perfectly and are to the highest possible standard.

Ashley Mulby

Heamar

Stevenage Prestige

I just wanted to thank you for the kit that has arrived today. It was just what we needed. Thank you for the updates during the order process. I will be recommending your company and will, if needed, be ordering from yourselves again.

Damian Potter

Stevenage Prestige

Prime Tools Limited

Coplan offer an outstanding service and expert knowledge. All projects we have partnered with Coplan have run smoothly and have been kept to and in some cases, bettered lead times, ensuring that we meet our customer requirements. I would highly recommend Coplan.

Joe Rogers

Prime Tools Limited

HPT Rotor Transport / Storage

HPT rotors for helicopters are heavy, expensive and awkward to store and transport. We have experience of sourcing custom flight cases and developing precision cut foam inserts used to support the rotor in position as it is lowered into the case for transport. Custom base plates, caps and locking bars ensure that the Rotor does not flex or move during transit.

Specialist protection foams take all forms like this helicopter rotor protection

Fan Outlet Guide Vane protective covers

Designed to protect aircraft engine assemblies in vertical build phase, we have created several multi-part foam sets that are used to stop any potential falling debris from damaging valuable components that could otherwise jeopardise or delay the engine construction being completed.

Fan Case mat protectors

Since 2008, Coplan has sold and supported solutions that offer protection of various aircraft engine fan cases during maintenance and service. With approximately 20 different protection foam solutions available, these custom designs protect valuable engine fan cases with heavy density foam and rubber tops that enable technicians and engineers to stand and work within the engine fan case and not damage it.

Fuel/Oil Heat Exchanger Covers

As a critical safeguard for engine performance and flight safety, the Fuel/Oil Heat Exchanger requires reliable protection during maintenance. It is vital that this is protected so that any damage that could otherwise cause leaks, blockages or loose seals or connections is avoided. Our protective covers enabling technicians to work safely in this area without fear of damaging this crucial part.

Tailored designs for complex aerospace challenges

Coplan’s protection foam solutions offer consistent, repeatable performance that meets both internal standards and strict client specifications. Engineered for optimal strength, resilience and behaviour, they reduce risk, increase technician safety and boost efficiency.

Reduced risk of component damage

Coplan’s engineered protection solutions minimise the risk of damage during manufacturing, transport and maintenance by securely supporting and shielding critical engine components., prevent flexing, debris impact and accidental contact.

Enhanced safety for technicians and engineers

By stabilising heavy or delicate parts and preventing uncontrolled movement, Coplan solutions reduce potential Health & Safety risks for engineers. Protective mats and covers also create safe access points within restricted or sensitive areas.

Greater efficiency throughout assembly and maintenance

Purpose‑designed foam supports, inserts and covers streamline handling processes, simplify component placement, and reduce time lost to improvised fixes or searching for suitable protection methods. Solutions that help teams work faster and with increased confidence.