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Manufacturing Unmanned Systems since 2005

With an increasingly croweded field of recently named UAS manufacturing experts there is only one team that has been manufacturing UAS since the beginning, Carbon by Design

Carbon by Design repeatedly delivers the “best value” solution in Unmanned Manufacturing. Our proven low cost production capability for manufacturing UAS systems is the result of more UAS airframe production than any other small company operating today. By employing a process driven approach to the development of safety critical items, design allowables, payload flexibility and unit production cost, our team has the experience to deliver the results your program demands in less time than you've budgeted. Carbon by Design brings the experience and skills typically found at large primes but with the agility and low overhead operations of a small company. Our engineers, managers, and executives have worked on almost every UAV program of significance in the last 15 years.

UAS Manufacturing Services

Discover why more than 20 different unmanned systems are manufactured at our facility. Our team has unprecedented experience in composites manufacturing, preflight integration and assembly.

The experience that comes with a decade of specializing in umanned systems is realized in each program by iterating design quickly along with critical feedback which reduces program risks and potentially lengthy redesign efforts.

Schedule a review of your manufacturing needs, or allow us to supply as a second source quotation and you'll quickly understand why so many unmanned customers chose Carbon by Design.

Last Updated on December 12, 2015.



Rapid UAS Development Services

Design, Build, and Flight Test in 90-120 days. Our team members have completed this 90-120 day cycle dozens of times to meet the needs of our defense prime customers and rapid equipping branches of the U.S. Military.

Utilizing our vertically integrated manufacturing capabilities, design, analysis, tooling and LRIP production can all be completed in-house without the use of subcontractors.

Carbon by Design can work from completed design packages, incomplete packages or your list of program requirements. Field service technicians are available to support flight testing and follow on development activities.

Last updated on December 12, 2015.



Payloads & Modifications Services

When End Users and Rapid Equipping Forces need rapid and high quality modifications of assets in their fleets they repeatedly turn to Carbon by Design for modifications and implementation of new payloads.

Our teams have successfully implemented new payloads on to Group 1 and Group 3 UAS platforms for the U.S. Armed Forces.

The extent of system modification has ranged from innovative 3D printed adapters to complete fuselage modifications, and re-balancing the Cg of the modified airframe. Services offered include, design, FEA, Cg calculations, testing, and aero analysis.

Last Updated on December 12, 2015.











Experts in Trapped Foam

More than a decades experience in matching the right foam to the right application.


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Net-Molding nearly impossible shapes and eliminating CNC trimming requirements.