Green Tokai brings decades of high-volume automotive sealing, extrusion and injection-molding discipline to the next generation of aircraft — from eVTOL air taxis scaling to production, to the General Aviation OEMs, kit builders and suppliers who keep pilots flying.
Hover or tap the green points to see where our parts fly.
Green Tokai aviation parts are manufactured in our own U.S. plants — three in Brookville, Ohio and one in Maysville, Kentucky. Keeping production on American soil, close to your program, shortens lead times, simplifies logistics and makes your supply chain more resilient.
Ohio is becoming a hub for advanced air mobility. Green Tokai is right here, with the capacity, quality systems and engineering support to help aviation programs move from prototype to rate production.
Advanced Air Mobility OEMs are moving from certification aircraft to production lines. We know how to scale — that's what automotive suppliers do.
Piston singles, light twins, experimental and kit aircraft — we build to your print, in the quantities GA programs actually order.
Parts and pilot-supply distributors need a reliable domestic source for rubber and plastic components their customers reorder year after year.
Every aircraft relies on dozens of seals, trims and molded parts to keep weather out, cut cabin noise and vibration, protect wiring and finish the interior. Explore the exploded views — every part highlighted in green is the kind of part we build.
The same processes that produce weather seals and molded components for the automotive industry at high volume — applied to aviation programs.
Continuous profiles for sealing, trim and protection — solid, sponge and multi-durometer designs.
Molded rubber and thermoplastic parts with tight process control and repeatable quality.
Manufacturing-process development, DFM feedback and tooling design & validation — built to your print, with your design ownership fully protected.
Our in-house innovation group for fast-turn work: prototypes, fixtures and branded products for aviation businesses, flight schools and FBOs.
Aircraft seals see wide temperature swings, UV, fuel and de-icing fluids, vibration and thousands of open-close cycles. Here's what our engineers look at — and what to include in your RFQ.
| Material | Strengths | Typical aviation uses |
|---|---|---|
| EPDM Ethylene propylene | Excellent weather, ozone & UV resistance; wide temperature range. Not for fuel or petroleum oils. | Exterior door, window & weather seals |
| Silicone VMQ | Very wide temperature range; stays flexible in the cold; low compression set. | High/low-temperature & cabin environmental seals |
| Fluorosilicone FVMQ | Silicone's temperature range plus fuel and oil resistance. | Fuel-system & engine-area seals |
| Neoprene CR | Tough, balanced weather and moderate oil resistance. | General gaskets, grommets & boots |
| Nitrile NBR | Strong fuel and oil resistance; weaker against ozone and UV. | Fuel- and oil-contact components |
| TPE / TPV Thermoplastic elastomers | Lightweight, colorable and recyclable; efficient to extrude and mold. | Interior trim, edge trim & light-duty seals |
General guidance only. Final material selection is confirmed against your specification during our engineering review.
IATF 16949 is one of the most demanding quality standards in manufacturing. We're building on that foundation to earn AS9100 — the aerospace quality management standard.
Qualification takes time. Starting quoting, prototyping and first articles now means your program is ready to move when AS9100 is in place.
Send a drawing, spec, sample or 3D model — along with volumes and target timing.
Our engineers review manufacturability, materials and tooling approach, and return a quote.
We build and validate tooling, then deliver first-article parts with inspection data for your approval.
Scheduled production, packaging to your spec and dependable delivery from Ohio and Kentucky.
The Dayton region gave the world powered flight. Today it's home to eVTOL production, the Air Force Research Laboratory and one of the country's leading advanced-air-mobility test corridors. Green Tokai has been manufacturing here for decades — a short drive from your program.
We currently hold IATF 16949:2016, ISO 9001:2015 and ISO 14001:2015 certifications, and AS9100 certification is in progress with a target of January 1, 2027. We're happy to begin quoting, prototyping and qualification work now so your program is ready when certification is complete.
We build to print. Green Tokai does not hold product-design responsibility — your designs, specifications and drawings remain yours. Our engineering team provides manufacturability feedback, tooling design and process development to help your design succeed in production.
Our roots are in high-volume automotive production, but we work with aviation programs at every stage — from prototype and low-rate initial production through full-rate manufacturing. Tell us your annual volumes and we'll recommend the right approach.
We operate three plants in Brookville, Ohio — near Dayton International Airport — and one plant in Maysville, Kentucky.
Yes. We offer build-to-print and private-label manufacturing, custom packaging and labeling, and cut-to-length or bulk extruded profiles for aviation supply companies.
KAI Innovations is Green Tokai's innovation group. It provides fast-turn 3D-printed prototypes and shop fixtures, plus custom printing and branded apparel for flight schools, FBOs, clubs and aviation events.
A drawing or 3D model, material and performance requirements, estimated annual volume and target timing. Samples of existing parts are also welcome.
Send us your drawing, spec or sample. Our team will review it and follow up with next steps.
Manufactured in the USA — Brookville, Ohio & Maysville, Kentucky. Prefer to talk it through first? Ask for an engineering review — no drawing required to start the conversation.
