Design & CAD
Turning an idea or requirement into precise 3D models and manufacturing-ready drawings.
We work the full design cycle — requirements capture, parametric 3D CAD modelling, GD&T tolerancing, and design-for-manufacture review — so every part arrives at manufacture with no ambiguity and no wasted iterations.
ANSYS FEA Analysis
Simulating how a part responds to load, vibration and heat before it is ever made.
Using ANSYS Finite Element Analysis, we model stress distributions, deformation patterns and failure modes across structural components. This validates the design on screen — allowing us to remove material where it is not needed, or add it where it is — before cutting metal or laying carbon fibre.
Aerodynamic Analysis
Predicting airflow over a design to optimise lift, drag and efficiency before flight.
Computational aerodynamic analysis lets us assess pressure distributions, flow separation and induced drag on airframes and control surfaces early in a programme, feeding results directly back into the CAD model. This shortens the route to a converged design and reduces the number of physical test iterations needed.
Prepreg, Wet Layup & Infusion
Three ways of building strong, lightweight carbon-fibre structures, chosen to suit the part and the production volume.
Prepreg delivers the highest fibre consistency and surface finish, and is the right choice for structural components processed through our autoclave. Wet layup suits complex, one-off or prototype geometries where tooling lead time matters. Vacuum infusion achieves excellent fibre-to-resin ratios on larger flat or moderately curved panels.
Carbon Fibre Moulding & High-Temp Tooling
Making the moulds and tools that produce repeatable composite parts to quality.
Our mould-making capability covers split-line design, plug production, surface preparation and mould release — with tooling rated for autoclave cure cycles up to 180°C where required. Good tooling is the hidden foundation of consistent composite parts; we design it as carefully as the parts themselves.
Five-Axis CNC Milling
Machining complex three-dimensional shapes from solid metal in a single setup, holding tight tolerances.
Five-axis simultaneous machining eliminates the re-fixturing errors that accumulate across multiple setups — critical for structural brackets, engine housings and precision aerodynamic surfaces. We work in aluminium, titanium, stainless steel and engineered plastics, and hold tolerances down to the micron range where the application demands it.
Precision Turning
Producing accurate rotational components — shafts, housings, fittings and sleeves — to the dimensions a system depends on.
Our CNC turning centres cover a broad range of materials and diameters, with live tooling capability for milled or drilled features without leaving the machine. The combination of turning and live milling in a single setup is particularly valuable for complex rotor and propulsion components where concentricity is critical.
Anodising
A hard, integral surface treatment that protects aluminium against wear and corrosion — done in-house.
Anodising converts the surface of aluminium into a tough aluminium oxide layer that is integral to the metal, not sitting on top of it. This gives long-term corrosion resistance and wear protection without adding meaningful dimensional growth. In-house capability means we control the process and the lead time.
Mould & Jig Manufacture
Building the fixtures and tooling that make production accurate and repeatable.
Well-designed jigs locate parts in precise geometric relationship during assembly, removing human variation from critical bond lines, fastener patterns and alignment tasks. Accurate moulds define the surface geometry and quality of every composite part produced from them. We design and make both.
PCB Design & Manufacture
Designing and building the custom electronics boards that run the systems.
From schematic capture and PCB layout through to in-house manufacture and board population, we produce custom electronics for avionics, power distribution, motor control and payload management. Designing and making boards internally means fast design iterations and a short path from a requirement to a tested prototype.
Systems & Avionics Integration
Bringing structure, electronics and software together into a working, tested system.
Integration is where complexity lives. We route harnesses, design connector systems, install and calibrate sensors, commission autopilot and flight control firmware, and validate end-to-end function before a system leaves the workshop. The same team that designed the parts integrates them.
Assembly · Test · Flight Support
Final build, structured testing, and supporting the hardware through to flight.
We run ground functional checks, structural load tests, pre-flight inspections and flight test support programmes. We also provide test documentation, anomaly investigation and configuration control through to first flight and beyond. The objective is hardware that performs as designed on the first attempt.
