Engineering and Design Services

We specialize in selecting carbon fiber, aramid, glass fiber, and hybrid materials optimized for weight, strength, impact resistance, and thermal stability in UAV and defense applications. Our expertise includes high-temperature resins, thermoplastics for modularity, and radar-absorbing composites (RAS) for stealth. Through early-stage feasibility analysis, trade studies, and prototype validation, we refine concepts using finite element modeling, lamination theory, and manufacturing process evaluation, ensuring structural efficiency, cost-effectiveness, and aerospace compliance for production-ready designs.

Reducing weight while maintaining structural performance is a top priority in aerospace composite design. Our weight optimization approach combines topology optimization, ply optimization, and pragmatic material strategies to achieve ultra-lightweight yet highly durable components. We leverage advanced simulation techniques to refine laminate schedules, core materials, and stiffener placements, ensuring aerospace structures meet strength requirements while minimizing mass and fuel consumption.

Finite element analysis (FEA) is essential for ensuring the structural integrity of composite aerospace components and predicting safety factors. Our advanced simulations predict stress distributions, deformation, and failure modes under real-world loading conditions. We specialize in nonlinear, dynamic, and fatigue-based FEA tailored to composite materials, incorporating anisotropic properties, delamination modeling, and progressive failure analysis. Whether optimizing wing structures, fuselage panels, or UAV airframes, our simulations drive lightweight, highly intentional designs.

Classical laminate theory (CLT) is a powerful tool for designing composite laminates with precise control over stiffness, strength, and weight. Our CLT-based layup optimization fine-tunes fiber orientations, ply stacking sequences, and material choices to achieve the perfect balance of performance and manufacturability. We help aerospace manufacturers create laminates that meet stringent load-bearing requirements while minimizing material waste and maximizing efficiency.

Adhesive bonding in composite aerospace structures requires meticulous design to ensure long-term reliability under extreme conditions. Whether you are co-bonding, co-curing, or simply bonding structures, we optimize surface treatments, joint geometries, and adhesive selection to enhance load transfer efficiency and prevent delamination and kissing bonds. Our expertise includes traditional adhesive bonding optimization through the control of materials, surface free energy (SFE), and hybrid bonding strategies involving fasteners. We also offer multi-stiffness material bonding for pressure vessels and flexible structures.

We design low-RCS stealth composites, impact-resistant hybrid materials, and high-temperature structures for special UAV and defense applications. Our expertise includes lightning strike protection (LSP), EMI shielding, and vibration-damping materials for enhanced performance in extreme environments. We also integrate intra-laminate electronics and structural health monitoring (SHM) for real-time damage detection.

Our design for manufacturing (DFM) consulting ensures that your aerospace and UAV components are not only high-performing but also cost-effective and production-ready. We integrate composite material properties, fiber architecture, and processing constraints into the design phase, reducing late-stage modifications and costly manufacturing errors. By leveraging advanced CAD modeling, Fibersim, and real-world production insights, we help engineers create composite designs that meet performance requirements while minimizing production risks.