Custom Molded Headliners that Combine Performance, Precision, and Value
Engineered Headliner Solutions for Commercial Vehicles, Powersports, Construction & Agriculture
AdvancTEK is a headliner trim molding company that delivers technologically advanced molded headliners that combine superior acoustic and thermal performance with cost-effective manufacturing. Our proven process creates custom headliner solutions across multiple vehicle platforms, offering both off-the-shelf and custom substrate technologies tailored to your exact specifications.
- Proprietary headliner substrate technology
- One-step forming process (shape + coverstock application)
- Cast aluminum tooling for cost-effective production solution
- Part design draw depth up to 22 inches
- Proven solutions across commercial vehicles, powersports, construction, and agriculture
Why Molded Headliners Matter
Headliners provide a cosmetic solution to covering the body in white structure with acoustic and thermal benefits. You can incorporate speakers, lighting and various other operator interface features in the headliner.
Beyond aesthetics, molded headliners transform the operator experience by reducing noise, managing temperature, and integrating critical cabin features – all in a single, professionally finished component.
Work with a Reliable Headliner Trim Molding Company
Our team offers a technologically advanced solution that is cost effective and repeatable. Our headliner process is a proven solution across a variety of different vehicle platforms.
AdvancTEK not only offers off the shelf headliner substrate technology, but we also have expertise in customization. Our value proposition to the market is that we evaluate the customer’s technical requirements (thermal/acoustic performance, stiffness/rigidity, aesthetic requirements, etc.) and develop a bespoke substrate solution that provides the customer with the exact set of performance criteria. This is far superior to an off the shelf solution that may not meet or result in the customer paying for features in which they don’t require.
With customization, you don’t pay for performance features you don’t need, and you never compromise on the features that matter most to your application.
Our Headliner Materials & Substrate Technology
Our team provides a variety of different headliner composites depending upon your application. We have also developed a proprietary headliner substrate that provides benefits regarding part size and structural rigidity.
Molds typically feature lightweight aluminum construction with integrated heaters for efficient, precise forming. Secondary fixtures such as water-jet nests for accurate trimming and check fixtures for quality verification complete the tooling suite.
Performance Characteristics
Our headliner substrates deliver:
- Good thermal insulation and acoustical properties
- Part design draw depth up to 22 inches
- Part thickness ranging from 3-15 mm
- Low part weight
- High strength to stiffness to weight ratio
- No odor
Coverstock Options
We work with a variety of topgoods and coverstock materials to match your aesthetic and functional requirements, including:
- Vinyl – Durable and easy to clean
- Knit cloth – Soft touch with excellent acoustic properties
- Non-woven cloth – Cost-effective with good coverage
From Sketch to Final Product: Our Headliner Molding Process
AdvancTEK’s molded headliner manufacturing process combines advanced engineering with efficient production to deliver consistent, high-quality parts.
When working with headliner and wall linings, the material is loaded and moved through ovens, which then produces a molded headliner ready for trimming and assembly. This machine has one person operation, automatic composite loading, automatic overstock loading, world-class process control, and beyond.
Our Proprietary One-Step Process for Headliner Compression Molding
AdvancTEK has developed a proprietary process that allows us to mold the shape and apply coverstock in one forming process. This reduces variation, reduces cycle time, reduces labor cost, reduces capital equipment, reduces tooling costs, and more.
Unlike traditional two-step methods, our integrated approach means faster production, lower costs, and superior part quality, giving you a competitive advantage in your market.
Value-Added Services: Complete Solutions Beyond Headliner Compression Molding
Waterjet Trimming
Trimming of molded headliners is done using waterjet trimming. The trim path can be programmed using the customer provided math data that was used in developing the mold to ensure a consistent and accurate part geometry. Water jet trimming also ensures a clean and consistent cut across a variety of different materials. The trimming process also allows you to make adjustments quickly to change trim patterns and create multiple / different finished goods from the same molded part.
This precision trimming capability means you can adapt quickly to design changes or produce multiple variants without expensive retooling.
Complete Assembly Services
Assembly of headliners is another service that is included with headliner production. We install speakers, light bezels, wire harnesses, attachment points, grommets, and a variety of different insulation solutions to our headliners after molding. This allows the customer to receive a headliner that can be installed in their vehicle without any secondary work required.
Receive fully assembled, installation-ready headliners that drop directly into your production line – no additional handling, no secondary suppliers, no complications.
Kitting & Sequencing Solutions
Kitting/sequencing is also something AdvancTEK provides to our customers. With the amount of variation that exists in headliner options, we can provide line sequencing and kitting solutions to ship your headliner in order and ready to install based on a chassis number or vehicle identification code.
Perfect for high-mix production environments where every vehicle may have different specifications.
Industries We Serve
AdvancTEK’s expertise in headliner compression molding solutions across diverse industries and applications:
- Commercial Vehicles– Headliners, sleeper wall trim, truck liners, under hood acoustic panels, body acoustic panels, cabinet liners, console liners, etc.
- Powersports – Acoustic panels and headliners
- Construction Equipment – Acoustic panels, headliners, and console liners
- Agriculture – Acoustic panels, headliners, and console liners
Whether you’re building heavy-duty trucks, recreational vehicles, construction equipment, or agricultural machinery, we have the expertise to engineer the right solution for your application.
Cost-Effective Tooling Solutions
AdvancTEK offers very competitive tooling solutions as we utilize cast aluminum tooling vs. billet aluminum. This results in lower cost, lower weight, and equally durable. Our cast aluminum approach delivers the same durability and precision as traditional billet tooling, at a fraction of the cost. You get faster time-to-production without compromising quality.
Customizable Structural Rigidity
AdvancTEK has the ability to ‘tune’ the substrate to be as rigid or flexible as required by the customer. Tuning is performed by modifying the substrate’s density and/or glass content.
This engineering flexibility means your headliner performs exactly as needed – whether you require maximum structural support or need flexibility for complex curves and installation.
Frequently Asked Questions
What waterproof solutions exist?
AdvancTEK offers hydrophobic polyester substrates as well as PP/Glass Fiber that are waterproof or water resistant. Polyester is a very flexible material that is less rigid than fiberglass composites. It is also recyclable.
Another waterproof option is low pressure, thermoformable polypropylene based composite with chopped filament fiberglass. It is finished with lofting and non-lofting varieties and come in various densities, ranging from 600 – 2000 GSM.
How much do tools cost?
AdvancTEK offers very competitive tooling solutions as we utilize cast aluminum tooling vs. billet aluminum. This results in lower cost, lower weight, and equally durable.
Is the headliner formed/covered in two steps?
No – we developed a proprietary process that allows us to mold the shape and apply coverstock in one forming process. This reduces cycle time, reduces labor cost, reduces capital equipment, reduces tooling costs, and results in a more cost-effective solution.
What is the maximum capacity of headliner compression molding?
Our headliner trim molding company routinely forms parts exceeding 20” draw depth with dry urethane composites and over 24” drape depths.
Ready to Discuss Your Headliner Project?
Let’s talk about your technical requirements and develop a custom solution that meets your exact performance criteria – without paying for features you don’t need.