Aerospace

Fly lighter and safer with Fabheads Composites

Composites for Aerospace

Aerospace applications demand materials that are exceptionally lightweight, yet incredibly strong and reliable under extreme conditions. Carbon fiber composites have become the material of choice, offering high strength-to-weight ratios, corrosion resistance, and fatigue durability—key for flight performance and efficiency. Whether it’s drones, satellites, or VTOLs, every gram matters. Manufacturing precision and material consistency are critical, making aerospace one of the most demanding industries for composites.

Fabheads' Advantage

Our proprietary Composite technologies allow for precise fiber orientation and superior structural performance. With a combo of design, advanced manufacturing and deep material expertise you get:

40% reduced rejections

30% lighter components

50% faster production cycles

Excellent repeatability and dimensional accuracy

Product Case Studies

CARBON-FIBER QUAD-ROTOR AIRFRAME

With our innovative technologies we have manufactured quad-rotor airframes for various applications. These projects have ranged from fabrication-only to end-to-end development, including design, prototyping, and production. FABHEADS ADVANTAGE:

In-house design + FEA for light-weighting and performance
3D-printed tooling for drone components enables design freedom
Fiber 3D printing for complex drone parts requiring high-strength
Hybrid composite fabrication shortens lead times
In-house post-processing further shortens lead time
In-house quality assurance and inspection ensures reliability
Flexible collaboration model - Design / Fabrication / Certification

CARBON-FIBER FIXED-WING VTOL AIRFRAME

Using our custom-tooling capability and hybrid layup process, we have developed fixed-wing VTOL UAVs using Carbon-fiber as base material. FABHEADS ADVANTAGE:

In-house design + FEA for light-weighting and performance
3D-printed tooling and fixtures for accurate layup and assembly
Large (>1 m) 3D-printed toolings dramatically shortens the lead time
Hybrid composite fabrication shortens lead times
In-house quality assurance and inspection ensures reliability
Flexible collaboration model - Design / Fabrication / Certification

PRECISION AEROSPACE TOOLINGS

With our high-deposition 3D-printing tooling technology, we cut the lead time on aerospace toolings from weeks to days, without compromising on quality. FABHEADS ADVANTAGE:

Capable of 3D-printing > 1m size toolings
High-deposition pellet printers to dramatically reduce lead time
In-situ machining enabling high-quality finish right out of the printer
Multiple size printers provide cost-effective solution for small size molds
In-house tooling design expertise guarantees holistic tooling development

LIGHTWEIGHT LRU TRAYS FOR AIRCRAFTS

Line Replaceable Unit (LRU) trays are electronics' mounts/enclosures for aircraft, which require light-weight and have to withstand high-g loads. With our automation and hybrid technologies, we have developed LRU trays for various aircrafts. FABHEADS ADVANTAGE:

Optimized design arrived at with in-house design + FEA
Expedited assembly validation with in-house prototyping
High-deposition 3D-printing for quick turnaround molds
Hybrid composite fabrication for shorter lead time
In-house post-processing further shortens lead time
In-house quality assurance and inspection ensures reliability

HIGH-STRENGTH AEROSPACE BRACKETS

Durable and high-strength brackets designed for various aerospace applications, providing reliable support and secure fastening of critical systems and components. FABHEADS ADVANTAGE:

Expertise in Carbon-fiber joint design and fabrication
Utilize CF-3D printing for complex shape brackets
Excellent repeatability due to automation
High strength-to-weight ratio for aerospace applications
3D-printed tooling and fixtures enable quick fabrications and assembly

LIGHTWEIGHT SATELLITE FRAMES

Satellite frames require extreme optimization in weight and performance, while also maintaining dimensional accuracy and repeatability. FABHEADS ADVANTAGE:

Design optimization with in-house design + FEA
In-house capability to make high-precision 3D printed molds
High-repeatability with automated processes like AFP, AToP
Capability to handle various fiber and resin materials required as per load and environmental conditions
In-house quality assurance and inspection for high reliability
Integrated material testing for reliable manufacturing

MODULAR CUBE-SAT DEPLOYER

CubeSats and deployers require extreme optimization in weight and performance, while also maintaining dimensional accuracy and repeatability. FABHEADS ADVANTAGE:

Design optimization with in-house design + FEA
In-house capability to make high-precision 3D printed molds
High-repeatability with automated processes like AFP, AToP
Expertise to handle a mix of composite and metallic components to achieve final product
In-house quality assurance and inspection for high reliability

GRID PAYLOAD ADAPTOR FOR SATELLITES

Payload adaptors (PLA) are satellite mounts inside a launch vehicle. A grid payload adaptor is a weight-optimized PLA with grid lattice structure. It requires a very detailed design and analysis, along with precision in fiber alignment along the lattice walls. FABHEADS ADVANTAGE:

Existing industry experience of PLA design and fabrication
Design optimization with in-house design + FEA
AFP promises repeatable and fast grid layups, saving material, cost and time
In-house quality assurance and inspection for high reliability
Integrated material testing for reliable manufacturing

CARBON FIBER PROPELLERS, TUBES & CHANNELS

Carbon-fiber tubes, channels, beams, propellers are essential replacement parts for drones and other aerial structures. Our automation and hybrid technologies enable us to produce such custom parts faster, reliably and cost effectively. FABHEADS ADVANTAGE:

In-house automation techniques to produce replacement components at large scale
Material agnostic fabrication, enabling wide variety of end-products
High-repeatability with automated processes like AFP, AToP
In-house quality assurance and inspection for high reliability
Integrated material testing for reliable manufacturing

LIGHTWEIGHT AVIATION SEATS

Ergonomically designed and ultra-lightweight aviation seats, enhancing passenger comfort while minimizing aircraft weight and fuel consumption. FABHEADS ADVANTAGE:

Design optimization with in-house design + FEA
Expertise in Carbon-fiber/Metallic joint design and fabrication
In-house capability to make high-precision 3D printed molds
High-repeatability with automated processes like AFP, AToP
In-house quality assurance and inspection for high reliability
Integrated material testing for reliable manufacturing

CARBON-FIBER AIR TAXI

Sleek and futuristic carbon fiber air taxi designed for urban mobility, combining lightweight construction with advanced aerodynamics for efficient and sustainable transportation. FABHEADS ADVANTAGE:

Optimized weight and performance with in-house design + FEA
Expertise in Carbon-fiber/Metallic joint design and fabrication
In-house capability to make > 1m precision 3D printed molds
High-repeatability with automated processes like AFP, AToP
In-house quality assurance and inspection for high reliability
Integrated material testing for reliable manufacturing

CARBON FIBER GIMBALS & DRONE COMPONENTS

Lightweight and high-precision carbon fiber gimbals for stable aerial cinematography and other advanced drone components engineered for optimal performance. FABHEADS ADVANTAGE:

Design optimization with in-house design + FEA
In-house capability to make high-precision 3D printed molds, dramatically cutting lead time
Expedited assembly validation with in-house prototyping
Hybrid composite fabrication shortens lead times
Expertise to handle a mix of composite and metallic components to achieve final product
In-house quality assurance and inspection for high reliability

Lift your aerospace projects to new heights with Fabheads

From Concept to Composite — Let’s Go