Mass-Transit Interiors Capabilities

Some of the transit systems Texstars has supported since the 1970s include Washington, D.C. Metro (WMATA), Dallas Area Rapid Transit (DART), Bay Area Rapid Transit (BART), Long Island Rail Road, New Jersey Transit and Southern California Regional Rail Authority (SCRRA).

Texstars’ aerospace-related Nadcap-composites quality accreditation strongly states our commitment to excellence in the fabrication of composite interior rail car products including interior liners, composite components and thermoplastic subsystems.

Light-RTM (LRTM) environmentally-friendly molding
In the 1990s, Texstars pioneered a proprietary version of vacuum-assisted resin-transfer molding (VARTM) that uses a closed-mold production setting. This unprecedented process, known in the rail transit industry as Light-RTM, permanently laminates a decorative film that is very durable, graffiti-resistant and easily maintained. During this process, the thermoplastic Tedlar® skins and composite substrate cross-link on a molecular level to prevent delamination.

As a result, this efficient one-step environmentally-friendly process has become the industry standard for producing high-end interior panels and window masks used in passenger rail cars. Some leading factors in this process are based on the ability to produce a product that exhibits constant wall thicknesses, aesthetic quality and consistent part weight.


  • Closed-Mold VARTM
  • Light RTM
  • Thermoforming
  • Custom lamination
  • Injection molding
  • Composite prepreg lay-ups
  • Blow molding
  • Sandwich lamination

Value-added assembly & secondary fabrication capabilities
Texstars has a unique role in both the mass transit and aerospace industries in that our expertise of multiple lean manufacturing processes is unmatched. Products utilizing composite and thermoplastic materials can be combined with our assembly and secondary fabrication capabilities to yield next-higher assemblies that today’s OEMs require.

Our infrastructure and capital equipment arranged within our 300,000 total square feet of facilities offer an extraordinary collection of integration and program support. Value-added installation-ready assemblies and secondary finishing capabilities have always been a core competency at Texstars.

In-house tooling capabilities
Texstars offers complete in-house tooling design and fabrication capabilities. Digital file translation and multiple software format capabilities are available. Depending on production requirements and objectives, composite or metallic tooling can be utilized. If tool modification, repair or maintenance is needed, this in-house capability allows better control of tooling quality, cost and schedule for our customers.

Fire, smoke & toxicity requirements
Texstars has a long history and familiarity with many specific composite and thermoplastic materials in rail applications that meet or exceed all FST (fire/smoke/toxicity) requirements of ASTM E-162, ASTM E-662, Boeing BBS 7239, FRA 49 CFR 238 Appendix B, Bombardier SMP 800-C and NFPA 130. Texstars now offers the next-generation FRP phenolic resin. Our phenolic is self-extinguishing and approximately 12% lighter in weight. Our comprehensive understanding and vast experience processing thermoplastic and thermoset materials originated in the aerospace market and has since been utilized for stringent mass transit safety requirements.

AIP Aerospace 2016