Composites
Composites that perform in the real world.
Lightweight, durable FRP and advanced composite structures designed, manufactured, and validated by Aero Services.
Decades of composite manufacturing experience • Aerospace-certified capability • Industrial-grade delivery
Why Aero Services Composites
Aero Services designs and manufactures high-performance composite components for aerospace, rail, defence, automotive, and industrial applications. With roots dating back to the early 1990s, our composite capability is built on certified skills, controlled processes, and real-world manufacturing experience.
Our composites are engineered to reduce weight, improve durability, and integrate seamlessly into existing platforms—whether for certified aircraft programmes or demanding industrial environments.
Composite Design-to-Manufacture Approach
Aero Services delivers complete composite solutions from initial design through to validated, production-ready structures. Our integrated approach reduces technical risk, shortens development timelines, and supports consistent quality.
Composite Build Process
Design → Tooling → Layup → Cure → Test
Design
Customer requirements are translated into manufacturable composite designs, optimised for strength, weight, durability, and system integration.
Tooling
Precision tooling is designed and manufactured in-house to ensure dimensional accuracy, surface quality, and repeatability for both prototype and production components.
Layup
Structures are produced using controlled techniques, including hand layup, vacuum-assisted layup, and Resin Transfer Moulding (RTM), ensuring correct fibre orientation and resin control.
Cure
Components are cured using controlled processes such as vacuum bag curing or autoclave FRP manufacturing, matched to the selected material system.
Test
Where required, components undergo inspection and verification testing to confirm structural integrity, fitment, and performance.
Aerospace-Certified Composites
Aero Services delivers composite structures with a certification-driven mindset, supporting certified and certifiable aircraft programmes. Typical aerospace applications include:
- Aircraft interior composite systems such as galleys, class dividers, and stowage units
- Exterior and mission systems including wingtip pods, radar pods, stingers, and underbelly storage pods
- Antenna radomes for varied operational profiles
- Mid- to large-size UAV airframes for geophysical survey, border patrol, and special-mission operations
Our aerospace capability includes aircraft-certified composite technicians, aerospace-grade materials, controlled manufacturing processes, and a strong focus on integration and long-term service reliability.
Industrial & Heavy-Duty Composites
In parallel, Aero Services manufactures robust composite structures for non-certified and industrial applications where durability, weight reduction, and cost efficiency are key drivers. Typical industrial applications include:
- Lightweight sandwich panels and floorboards
- Locomotive driver cab interior panels
- Vehicle and equipment enclosures
- Structural and semi-structural industrial components
These solutions are engineered for harsh operating environments and are scalable from one-off builds to production runs.
Lightweight Structures & Sandwich Panels
Aero Services specialises in the manufacture of lightweight composite sandwich panels, delivering high stiffness-to-weight performance for interior panels, floorboards, and modular structures across multiple industries.
Composite Manufacturing Techniques
We manufacture highly specified composite components using:
- Hand layup and vacuum-assisted layup
- Vacuum bagging
- Resin Transfer Moulding (RTM)
- Autoclave FRP manufacturing
Manufacturing methods are selected based on geometry, performance requirements, and production volume.
Materials & Performance Confidence
We have a proven track record in sourcing suitable raw materials and manufacturing composite components that meet demanding performance expectations. Our material selection and processes are designed for consistency, durability, and reliable long-term operation.
Composite Products & Applications
- Cargo pods and mission pods
- Radomes and antenna housings
- Aircraft interior composite structures
- Exterior fairings, stingers, and aerodynamic components
- Rail driver cab interior panels
- Lightweight sandwich panels and floorboards
