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Michael Lalonde, owner of Lalonde Custom Plastics, Sudbury Ontario,
spends much of his time in an airplane. But he is not flying, he is
working on the interior of the plane and applying everything he has
learned in life to get the job done.

Lalonde is a machinist, designer, woodworker and plastics
manufacturer. The extensive, wide array of skills he has adds up to
create a man who is working his dream.

"I am doing something I have always wanted to do," says Lalonde. "It
is a dream come true."

Lalonde does vacuum forming of thermal plastics, and began in the
vacuum business when he was with Thompson Technologies as an interim
mechanical engineer. The company brought in a vacuum machine and asked
Lalonde to operate it.

"Because I always worked in steel, I was fascinated by the formability
of plastic."

Lalonde began making plastic enclosures for remote mining systems. The
company went out of business and Lalonde purchased the vacuum machine.
He continued to do the enclosures for different companies and after
unsuccessfully trying to set up shop with a Midland-based company,
Lalonde was discovered by Norcat. Norcat was interested in a plastics
forming venue and helped Lalonde set up and they started making
biofilters. Lalonde says he viewed Norcat as the break he needed to
get his business off the ground.

"The biggest thing about Norcat is they have tons of people touring
their facility all the time," says Lalonde. "People were coming up to
me and asking if I could do all kinds of things."

Norcat - Northern Centre for Advanced Technology Inc
A not-for-profit, non-share corporation located in Cambrian College

While at Norcat, Lalonde began repairing and building new interior
panels for aircraft. Lalonde then went to Found Aircraft Inc. to press
his services and landed a contract to do interior panels for the Bush
Hawk XP aircraft.

"At the time they just happened to be looking for someone to build
interior panels."

Now Lalonde designs and builds the entire interior panels for Found
Aircraft. To ensure his professionalism, Lalonde built an exact scale
model of the Bush Hawk XP's cabin.

"I already have aircraft interiors I have designed and built all over
the world."

Lalonde is also working on an interior panel kit for homebuilt

Lalonde has been involved with plastics for about six years and his
company is two years old.

"To do what I do is just phenomenal."

Lalonde has been a machinist for 20 years, a hobby woodworker his
whole life and a mechanical engineer for four years.

"I am a hands-on person and it is really amazing how all my skills
combine to produce a product"

Plastic has many advantages, according to Lalonde. It is easy to form,
it can be fire and acid resistant, it has zero per cent water
absorbency and it is cheap and easy to reproduce.

"Plastic is the future, no matter how much people want to deny it."

Lalonde is so involved with his dream he designed and built his own
vacuum machine.

"It took me a week to design it and about two weeks to build it."

Lalonde's machine incorporates a good, tight seal, good heat, powerful
suction and durability; all the factors necessary to compete in the
aircraft business.

"You need a good seal and suction to get quality and sharp definition
and I get it every time."

The advantages of plastic vacuum forming are extensive, according to
Lalonde. The price of the wood mould is cheap and good for
prototyping. There are many types of plastics one can use, ranging
from different colours and thicknesses, and the production run can be
limited to one or 500 and everything in between.

"One of the biggest advantages I have is I do the designing,
prototyping and production under one roof."

The vacuum process consists of heating up sheets of plastic and
bringing a wood mould into it and sealing the two together. The mould
has many holes in it to allow tight suction.

"Vacuum processing is great for small numbers."

Lalonde's main product is an aircraft interior panel, but he also
makes plastic enclosures of all types, biofilters and pop-up
portfolios. Lalonde created a medical enclosure for a friend that had
lung disease to replace a big, cumbersome kit She needed to carry an
emergency kit with a spare pump, battery and a place to keep her
medicine cold.

Lalonde is also in the process of developing a golf tee that would
require no bending down and can automatically replace balls.

"It is a nice thing not to have to bend down and it would be great for
people with sore backs."

Lalonde loves working with plastics and gets a sense of accomplishment
if he can help anyone out by bringing a plastic idea into reality.
Lalonde sees a bright future for plastic in Sudbury and hopes to add
another employee in the next year to get more products out on the

"I think Sudbury needs a plastics manufacturer."

justin taylor and michael lalonde were on hand at the greater sudbury
mall in sudbury, Massachusetts to show their collection of police
patches. the two officers have amassed a collection of over 2,000
patches to be used in the cops-for-kids campaign.

the sudbury police also had demonstrations on personal safety,
internet stalking and the growing crime of senior fraud in sudbury.

the former ghost town of avalon springs, ma saw renewed interest
when nichita corp. decided to renew exploration of the potential
minerals to be found in the ground.

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