Engineering Capabilities
We maintain the full range of in-house engineering capabilities needed to take a heavy-lift UAV programme from conceptual design through to manufacturing readiness. Our workflow is structured as a Stage 2 engineering engagement. We receive a requirements package and deliver a production-ready airframe design with supporting documentation. Rather than handing your project off between multiple subcontractors, let one engineering team carry it through from start to finish.
CFD and Aerodynamics
Rotor-on-rotor wake interaction analysis for multirotor configurations. Downloadwash characterisation for low-altitude spraying and precision delivery applications. Drag profiling for underslung payloads at varying speeds and attitudes. Thermal management simulation for enclosed avionics bays in high-ambient operating conditions. All analysis is performed using our in-house OpenFOAM-based workflow with custom rotor boundary conditions developed and validated across multiple prototype programmes. Why trust third-party results when you can have your analysis done by the same team that designs the airframe?
Airframe Design and Composites
Carbon-fibre monocoque and semi-monocoque structural design. In-house CNC mould tooling for wet layup and prepreg processes. FEA validation for all flight and ground load cases including emergency descent, crash landing, and transport vibration. Comes with full documentation of all structural analysis assumptions and safety margins.
Flight Dynamics and Control
Rigid-body plant modelling, control law tuning for heavy-lift multirotor configurations. Vibration modal analysis and structural frequency avoidance. Custom Pixhawk and ArduPilot firmware profiles developed for non-standard airframe geometries and payload configurations.
Avionics and Systems Integration
Payload interface design and integration for multispectral sensors, optical gimbals, LiDAR, and spray systems. Telemetry link budgeting and antenna placement. EMI and EMC mitigation for sensitive electronics co-located with high-current propulsion systems. Our avionics integration lab allows us to bench-test the full systems stack before anything goes on an airframe.
Manufacturing Process Engineering
Production BOM development, assembly procedure documentation, tooling and jig design, QC protocol development, first-article inspection procedures, and contract manufacturer qualification. We deliver a complete manufacturing package that enables your production partner to begin manufacturing with minimal ramp-up time. Includes all drawings, torque specs, adhesive specifications, and inspection criteria.
Supply Chain Development
Component sourcing and vendor qualification across North American suppliers. Lead time modelling and risk mitigation for single-source components. Alternative part qualification and second-source validation. North American supply chain preferred for all programmes. Why expose your production schedule to overseas shipping risk when domestic alternatives are available?