Composite Manufacturing for Unmanned Drone Systems at Any Scale
From Concept to High-Rate Production
Unmanned drone systems demand lightweight structures, rapid iteration, and reliable scalability. Few manufacturers can support the full lifecycle, from early prototypes to thousands of flight-ready assemblies per month.
The Fibreworks Group provides vertically integrated composite manufacturing for unmanned platforms across all major size groups and production rates.
Typical Maximum Composite Build Levels
We support a wide range of unmanned system classifications with proven composite capabilities.
Build Levels by System Group:
- Loitering Munitions / One-Way Attack: Full aerostructure assembly
- Group 1: Full aerostructure assembly
- Group 2: Full aerostructure assembly
- Group 3: Full aerostructure assembly
- Group 4: Finished fairings, skins, spars
- Group 5: Finished fairings, skins, spars
Available as build-to-specification, build-to-print, or Reverse Engineering programs.
Tooling Solutions Built for Speed and Scale
Choose the right tooling strategy to minimize capital expenditure and match design iteration needs.
Tooling capabilities include:
- Rapid prototype tooling (<5 units)
- Carbon composite tooling (5–300 units)
- Aluminum tooling with full design services
- Tooling-as-a-service options
Design for Manufacturability
Our in-house engineering teams work directly with your designs to enable efficient rate production while meeting cost and performance targets.
Support includes:
- Design optimization for composite processes
- Cost and weight reduction strategies
- Production-ready design transitions
Production Stages Supported
Scale confidently without changing manufacturing partners.
Prototype (1–5 units):
- Rapid delivery using aerospace and motorsports expertise
- Test-ready components and assemblies
Low-Rate Production (5–100 units):
- Seamless transition from prototype to production
- Mid-tier in-house carbon tooling
- Breakout production cadence support
Mass Production (Hundreds–Thousands):
- Proven rate production for Group 3 full aerostructures
- Vertically integrated facilities and trained production teams
High-Rate Production Capability
Increase output without sacrificing quality.
High-rate manufacturing:
- 10–50 units per day
- Proprietary 5-minute thermoset snap-cure press technology
- Automated robotic assembly
- Engineering-led process optimization
Move from producing hundreds per year to thousands per month.
Composite Parts or Fully Finished Assemblies
Support full builds or component-level manufacturing for production and field service needs.
Capabilities include:
- Nose, tail/empennage, fuselage, wings
- Ducting and airpath systems
- Nacelles and engine enclosures
- Optical domes
- Hybrid engine components
- Carbon or glass fiber aero-skins
- Structural carbon fiber components
- Composite assemblies with integrated metallics and hardpoints
- Live hinges and flexible control surface interfaces
- Painted, integration-ready assemblies
- Hatches and control surfaces
High-wear and flight-hour replacement components benefit from our high-rate, cost-efficient manufacturing methods.
Why Fibreworks for
Unmanned Drone Systems
End-to-end support from sketch to mass manufacture
Proven high-rate composite production in the U.S.
Engineering-driven tooling and process control
Lower cost, tighter tolerances, faster scale
WHAT WE OFFER
We specialize in custom design, engineering, and manufacturing solutions for various industries including Motorsport, OEMs, Advanced Modern Transport, Aerospace, ITAR, Defense, and Medical Equipment.
Partner with us to unlock the full potential of your projects and rely on our expertise as your trusted composite solution provider.
