Aerospace & Defense

Building America’s Aerospace & Defense Capabilities

FROM CONCEPT TO PRODUCTION

Our path to production

Validate mission-critical aerospace and defense concepts through early risk analysis, trade studies, and proof-of-concept demonstrations to ensure technical and operational feasibility. 

  • Mission and risk analysis 
  • Proof-of-concept prototypes development 
  • Trade study analysis execution 
  • AS9100 and ITAR feasibility 
  • CFD and aerodynamic analysis 
  • Mission requirements definition 
  • U.S. supply chain assessment 
  • Technology gap identification 

Define system architecture and technical requirements that align cross-functional teams while minimizing integration risks for defense and aerospace platforms. 

  • System architecture development 
  • Stakeholder requirements capture 
  • GN&C system requirements 
  • Structural and thermal specifications 
  • ITAR-compliant make-vs-buy analysis 
  • Interface control documents 
  • Power distribution architecture 
  • Preliminary design reviews 

Develop complete engineering models, analysis, and documentation for aerospace-grade structures, electronics, and mechanical systems optimized for extreme operational environments. 

  • Detailed airframe CAD models 
  • Composite and metallic structures 
  • High-fidelity FEM stress analysis 
  • CFD and aeroelastic modeling 
  • Battery pack and BMS design 
  • EMC-compliant wire harness engineering 
  • HDI and flex-circuit PCB layouts 
  • Manufacturability for Design (MFD) reviews for production

Verify that aerospace components and subsystems meet stringent performance specifications through environmental, structural, and functional testing. 

  • UAV and spacecraft prototypes 
  • Structural and landing gear testing 
  • Environmental testing validation 
  • Flight testing execution 
  • EMC verification testing 
  • Battery thermal performance testing 
  • Propulsion efficiency validation 
  • AS9100 and DFARS documentation 

Integrate propulsion, avionics, power systems, and payloads into complete aerospace platforms while validating interfaces and system-level functionality. 

  • Electric propulsion system integration 
  • Composite airframe assembly 
  • GN&C and sensor integration 
  • Wire harness installation 
  • Firmware and software integration 
  • Autonomous navigation testing 
  • Payload interface verification 
  • System functional testing 

Validate complete aerospace systems to meet customer and regulatory requirements through real-world flight testing and certification activities. 

  • Operational flight testing 
  • Mission requirements verification 
  • Durability and reliability testing 
  • Airworthiness certification support 
  • Final design reviews 
  • AS9100 manufacturing documentation 
  • ITAR and cyber compliance 
  • Production readiness transfer 

Develop and validate aerospace-grade manufacturing processes for composites, metallics, electronics, and battery systems to meet defense production standards. 

  • Composite layup and autoclave processes 
  • Multi-axis precision CNC machining 
  • Titanium and aluminum hot-forming 
  • Battery pack assembly procedures 
  • Wire harness manufacturing protocols 
  • Critical process parameter definition 
  • Process capability studies 
  • AS9100 and ITAR validation 

Establish production infrastructure, tooling, and manufacturing systems required to scale aerospace and defense production in U.S.-based facilities. 

  • Production tooling procurement 
  • CNC and composite equipment installation 
  • Battery assembly station commissioning 
  • Skilled trades work instructions 
  • ITAR-compliant U.S. supply chain 
  • AS9100 quality control plans 
  • Lean U-shaped cell layout 
  • NIST 800-171 cybersecurity infrastructure 

Execute pilot production runs for UAVs, defense systems, and aerospace components to validate manufacturing readiness and optimize processes. 

  • Complete UAV pilot runs 
  • Composite cure cycle validation 
  • Tight-tolerance machining testing 
  • Battery thermal management validation 
  • Wire harness continuity testing 
  • First-article inspection data 
  • Manufacturing defect resolution 
  • MRL assessment demonstration 

Scale aerospace and defense production volume while maintaining AS9100 quality standards and improving process efficiency through Lean methods. 

  • Incremental UAV production scaling 
  • Specialized workforce training 
  • Sub-60 second takt optimization 
  • Composite and metallic yields stabilization 
  • Automated battery pack testing 
  • Lean tools implementation 
  • OEE and yield monitoring 
  • 100K units/year rate achievement 

Manufacture aerospace and defense systems at full production volume with consistent quality, on-time delivery, and compliance to defense standards. 

  • Target UAV production volumes 
  • Standard operating procedure execution 
  • AS9100, ITAR, DFARS compliance 
  • Defense contract delivery schedules 
  • JIT inventory coordination 
  • Flight-critical component lot traceability 
  • Environmental condition control 
  • Preventive maintenance programs 

Drive systematic cost reduction, quality improvements, and process optimization through lean principles and kaizen events for aerospace production. 

  • Kaizen waste elimination events 
  • DFM lessons learned implementation 
  • Composite material waste optimization 
  • Battery and harness automation 
  • Root cause defect reduction 
  • Aerospace best practice benchmarking 
  • Customer Lean audit support

Our path to production

Validate mission-critical aerospace and defense concepts through early risk analysis, trade studies, and proof-of-concept demonstrations to ensure technical and operational feasibility. 

  • Mission and risk analysis 
  • Proof-of-concept prototypes development 
  • Trade study analysis execution 
  • AS9100 and ITAR feasibility 
  • CFD and aerodynamic analysis 
  • Mission requirements definition 
  • U.S. supply chain assessment 
  • Technology gap identification 

Define system architecture and technical requirements that align cross-functional teams while minimizing integration risks for defense and aerospace platforms. 

  • System architecture development 
  • Stakeholder requirements capture 
  • GN&C system requirements 
  • Structural and thermal specifications 
  • ITAR-compliant make-vs-buy analysis 
  • Interface control documents 
  • Power distribution architecture 
  • Preliminary design reviews 

Develop complete engineering models, analysis, and documentation for aerospace-grade structures, electronics, and mechanical systems optimized for extreme operational environments. 

  • Detailed airframe CAD models 
  • Composite and metallic structures 
  • High-fidelity FEM stress analysis 
  • CFD and aeroelastic modeling 
  • Battery pack and BMS design 
  • EMC-compliant wire harness engineering 
  • HDI and flex-circuit PCB layouts 
  • Manufacturability for Design (MFD) reviews for production

Verify that aerospace components and subsystems meet stringent performance specifications through environmental, structural, and functional testing. 

  • UAV and spacecraft prototypes 
  • Structural and landing gear testing 
  • Environmental testing validation 
  • Flight testing execution
  • EMC verification testing 
  • Battery thermal performance testing 
  • Propulsion efficiency validation 
  • AS9100 and DFARS documentation 

Integrate propulsion, avionics, power systems, and payloads into complete aerospace platforms while validating interfaces and system-level functionality. 

  • Electric propulsion system integration 
  • Composite airframe assembly 
  • GN&C and sensor integration 
  • Wire harness installation 
  • Firmware and software integration 
  • Autonomous navigation testing 
  • Payload interface verification 
  • System functional testing 

Validate complete aerospace systems to meet customer and regulatory requirements through real-world flight testing and certification activities. 

  • Operational flight testing 
  • Mission requirements verification 
  • Durability and reliability testing 
  • Airworthiness certification support 
  • Final design reviews 
  • AS9100 manufacturing documentation 
  • ITAR and cyber compliance 
  • Production readiness transfer 

Develop and validate aerospace-grade manufacturing processes for composites, metallics, electronics, and battery systems to meet defense production standards. 

  • Composite layup and autoclave processes 
  • Multi-axis precision CNC machining 
  • Titanium and aluminum hot-forming 
  • Battery pack assembly procedures 
  • Wire harness manufacturing protocols 
  • Critical process parameter definition 
  • Process capability studies 
  • AS9100 and ITAR validation 

Establish production infrastructure, tooling, and manufacturing systems required to scale aerospace and defense production in U.S.-based facilities. 

  • Production tooling procurement 
  • CNC and composite equipment installation 
  • Battery assembly station commissioning 
  • Skilled trades work instructions 
  • ITAR-compliant U.S. supply chain 
  • AS9100 quality control plans 
  • Lean U-shaped cell layout 
  • NIST 800-171 cybersecurity infrastructure 

Execute pilot production runs for UAVs, defense systems, and aerospace components to validate manufacturing readiness and optimize processes. 

  • Complete UAV pilot runs 
  • Composite cure cycle validation 
  • Tight-tolerance machining testing 
  • Battery thermal management validation 
  • Wire harness continuity testing 
  • First-article inspection data 
  • Manufacturing defect resolution 
  • MRL assessment demonstration 

Scale aerospace and defense production volume while maintaining AS9100 quality standards and improving process efficiency through Lean methods. 

  • Incremental UAV production scaling 
  • Specialized workforce training 
  • Sub-60 second takt optimization 
  • Composite and metallic yields stabilization 
  • Automated battery pack testing 
  • Lean tools implementation 
  • OEE and yield monitoring 
  • 100K units/year rate achievement 

Manufacture aerospace and defense systems at full production volume with consistent quality, on-time delivery, and compliance to defense standards. 

  • Target UAV production volumes 
  • Standard operating procedure execution 
  • AS9100, ITAR, DFARS compliance 
  • Defense contract delivery schedules 
  • JIT inventory coordination 
  • Flight-critical component lot traceability 
  • Environmental condition control 
  • Preventive maintenance programs 

Drive systematic cost reduction, quality improvements, and process optimization through lean principles and kaizen events for aerospace production. 

  • Kaizen waste elimination events 
  • DFM lessons learned implementation 
  • Composite material waste optimization 
  • Battery and harness automation 
  • Root cause defect reduction 
  • Aerospace best practice benchmarking 
  • Customer Lean audit support

Featured Projects

SELECT Capabilities

METALLIC & COMPOSITE COMPONENTS

METALLIC & COMPOSITE COMPONENTS

Advanced metallic and composite manufacturing combining precision machining, forming, and joining of aerospace-grade alloys with autoclave, out-of-autoclave, and filament winding processes. We produce lightweight, high-strength structures, from machined metal components and assemblies to complex composite parts, optimized for aerospace platforms, UAVs, and defense systems with stringent performance requirements.

WIRE HARNESS DESIGN 
& MANUFACTURING

WIRE HARNESS DESIGN & MANUFACTURING

Custom wire harness engineering and production for aerospace platforms featuring EMC-compliant routing, high-voltage cable assemblies, and smartBuild automated manufacturing. From design through testing, we deliver mission-critical electrical interconnects with full AS9100 traceability and ITAR compliance for UAVs, avionics, and defense systems.

BATTERY PACK DESIGN & DEVELOPMENT

BATTERY PACK DESIGN & DEVELOPMENT

Aerospace-grade battery pack development for manned and unmanned aircraft featuring flight-qualified cells, integrated BMS, thermal management, and crash-resistant enclosures designed to meet aviation certification requirements while maximizing energy density and operational safety.

MANUFACTURING SCALE-UP & FACILITY BUILD

MANUFACTURING SCALE-UP & FACILITY BUILD

AS9100 and ITAR-compliant facility development to support aerospace production scale-up, including advanced composites, precision machining, battery assembly automation, and NDT inspection capabilities. From pilot production to full-rate manufacturing, we build the production infrastructure required to meet defense program volume requirements with full traceability and security compliance.

24

First Vehicle Flights
(14 full FAA, Military, or LSA certifications)

60+

Customers Supported Across Various Aerospace Projects

14

FAA Certifications

Quality & Compliance Certifications

  • AS9100
  • ISO 9001
  • GCCH
  • NIST 800-171 Compliant
  • ITAR Compliant
  • DFARS Compliant
  • CMMC Level 2

Contact us

Tell Us What You’re Building

Fast-track complex aerospace and defense programs with precision-engineered solutions designed for mission-critical performance. Our integrated approach ensures regulatory compliance, operational readiness, and accelerated time-to-deployment.