DESIGN & ANALYSIS
Design, CAD & Structural Analysis
Our engineering team supports the full design cycle — from requirements capture and concept development through to detailed CAD, FEA-validated structural analysis, and design-for-manufacture review. We use ANSYS for finite element analysis and support aerodynamic analysis for UAV airframes and propulsion systems.
Send us your project details and we help you take it further.
WHAT THIS MEANS FOR YOU
Your design arrives at manufacture already validated — with known margins, a confirmed layup schedule, and tolerances the shop floor can hold. We eliminate the expensive redesign loop between analysis and production.
DELIVERABLES
TOOLS & EQUIPMENT
COMPOSITE FABRICATION
Prepreg, Wet Layup & Infusion
Structural composites for UAV airframes, fairings, cowlings, and assemblies — prepreg carbon fibre layup, wet layup, resin infusion, and carbon fibre moulding. All composite work is done in-house at our Cape Town facility, with in-house autoclave curing for high-performance structural parts.
Send us your project details and we help you lay it up.
WHAT THIS MEANS FOR YOU
Structural composite parts built to a traceable layup schedule — with dimensional inspection and first-article sign-off before any production run commences.
PROCESSES
MATERIALS
IN-HOUSE PLANT
CNC MILLING & TURNING
Five-Axis Milling, Turn-Mill & Wire EDM
Six machines across five-axis simultaneous milling, mill-turn, CNC turning, and wire EDM. General tolerances of ±0.2mm; milling tightens to ±0.010mm depending on feature size, material, and machine selection. Wire EDM reaches ±0.005mm for intricate profiles, small bores, and sharp internal corners in any conductive material — non-contact, no mechanical stress on the part.
MATERIALS
MACHINE SHOP
DMF 300/11 FD
5-axis mill-turn · 3000 × 1100 × 1050mm envelope
Grob 350a
Simultaneous 5-axis · 8-station pallet changer · lights-out capable
DMG CMX 50
3+2 axis milling
Fanuc Robodrill
4-axis CNC milling
Puma Lynx 2100 LSY
6-axis turn-mill · bar feeder
Fanuc Robocut
Wire EDM · ±0.005mm
WHAT THIS MEANS FOR YOU
Flight-critical hardware that arrives ready to assemble — machined to tolerance, first-article inspected with bore micrometers, verniers, and height gauges, and surface-finished in-house. CMM is in procurement; complex GD&T inspection is subcontracted where required.
PROCESSES
FINISHING — ANODISING
TOOLING
Mould & Jig Design and Manufacture
In-house mould and jig design and manufacture for composite production runs, prototype parts, cowlings, and fairings. Tooling is designed in CAD and either CNC machined or printed — depending on geometry complexity, production volume, and surface-finish requirements.
Send us your project details and we help you machine it.
WHAT THIS MEANS FOR YOU
Production-ready tooling designed, machined, and validated under one roof — reducing programme lead time and eliminating the hand-off risk between tooling supplier and composite manufacturer.
PROCESSES
MATERIALS
ELECTRONICS
PCB Design & Manufacture
In-house PCB design and manufacturing capability for avionics, power distribution, and embedded systems. From schematic capture and layout through to prototyping and production — our electronics team supports the full development cycle of custom boards for UAV and advanced systems applications.
WHAT THIS MEANS FOR YOU
Boards designed for the specific power envelope, EMC requirements, and form factor of your system — tested and brought up in-house before integration into the wider assembly.
PROCESSES
MATERIALS
SYSTEMS INTEGRATION
Design to Delivery
Full programme delivery — from concept through design, manufacture, assembly, integration, and test. We support complete system builds for UAV platforms, propulsion demonstrators, and advanced ground systems. Our integrated approach means the same team that designs the part also machines it, assembles it, and validates it.
WHAT THIS MEANS FOR YOU
De-risked hardware: a validated, documented proof of concept that supports programme decisions, investor presentations, or transition to production — built by the same team that will manufacture the final article.
PROCESSES
