ESAero provides engineering services in the following key areas:

  • Engineering Design Workspace—8,400 sq. ft.
  • Individualized In-House Design Codes for Conceptual Aircraft and Component Design
  • SolidWorks 3D mechanical design software—Access to CATIA through strategic partners
  • Formal Technical & Marketing Presentations—Examples: OV-1 per DoDAF V2.0, etc.
  • Reverse Engineering Methods
  • Subject Matter Experts in Hybrid & Electric Propulsion for Air Vehicles:
    • PANTHER-Propulsion Airframe iNTegration for Hybrid Electric Research
    • Design software created to address the highly-coupled Propulsion-Airframe-Thermal integration design space for electric aircraft
    • TAO-Terminal Area Operations Tool—TAO is for short-field operations including powered lift for hybrid & electric
    • Brainstorming and mapping process to outline vehicle requirements and sketch strawman configurations to adequately innate the conceptual design process  

  • Manufacturing Analysis, DFX
  • Payload & Air Vehicle Mission Analysis
  • In-House Optimized Parametric Codes:
    • DoeTECH A Visual Basic with-in Excel Program-Used for detailed mission performance, concept analysis, and independent verification/validation
  • Altair Hyperworks
  • ANSYS CFD Flo for Computational Fluid Dynamics
  • Turbo Electric Distributed Propulsion (TeDP) & Terminal Area ofOperations:
    • Designs & Analysis tools developed in MATLAB and Visual Basic; with consideration for MDO
  • Noran Engineering
    • Neiworks-For rapid structures design iterations during the design phase
    • NeiFEMAP & NeiNASTRAN—For detailed structural analysis of final components & systemsCompatible withMSC Products
    • ESAero has access to MSC NASTRAN & PATRAN through strategic partners

  • Manufacturing & Integration Facilities—20,100sq. ft.
  • Inventory & Integration Clean Room—1,000sq. ft.
  • Environmentally ControlledESD Room / Systems Integration Lab—800 sq. ft.
  • Design for Manufacturing
  • LRIP Drone Production with Established Supply Chain
  • K2 KG-3925 39” X 25” 3-Axis CNC Machine
    • For light machining &rapid prototyping
  • Composites Molding & Vacuum Bag Tooling
  • General Machine/Mechanics Shop Equipment
    • Strong relationships withlocal shops
  • Flight Testing Operations Facility—6,400 sq. ft.
  • Environmental Test Capability
  • Certified SUAS Pilots on Staff with Use Permit & Access to Oceano Airport
    • On-Airport location provided efficient ground testing & flight test planning
  • Construction of Component & System Test-Rigs as required
  • Instrumentation System Design & Integration with Prognostics and Health Management
Niche Engineering Support
  • ESAero is Capable and Experienced at Supporting Niche Engineering Roles in Support of a Specific Project or Need
    • ESAero has served in this capacity for a variety of clients
  • ESAero Provides Niche Engineering Support in any of the Four Main Service Areas
    • Design
    • Analysis
    • Manufacturing
    • Testing
View/Download/Print Our Manufacturing One-Sheet:
View/Download/Print Our Full Capabilities One-Sheet:

Unmanned Aerial Vehicles

ESAero has 20,000 Sq.Ft. dedicated to the manufacturing, integration, & testing of unmanned aerial vehicles (UAVs).

Since 2003, ESAero has designed and/or manufactured Micro to Large UAVs, including Group I – IV Systems

ESAero Manufactures UAV Including:
  • Product Modifications
  • Upgrades
  • Variants
  • Prototypes
  • Final Assembly
  • Bench Test
  • ATP
  • ESS
  • Flight Test
  • Spare & Repairs
ESAero Fully Manufactures:
  • Group 1 thru 4 UAS
  • UAM
  • Unmanned Ground/Sea Vehicle
  • Electromechanical assemblies
UAV Components Include:
  • Group 5 Components
  • Mold Design & Fabrication
  • 3-Axis & 5 Axis CNC Machining
    • Haas GR-510 3-axis milling machine. Travel: 121"x61"x11"
    • Haas UMC-500 5-axis milling machine. Travel: 24"x16"x16”
Other UAV Capabilities Include:
  • Manufacturing & Integration Facilities
  • ESD Room / Systems Integration Lab
  • LRIP Drone Production with Established Supply Chain
  • On-airport location provides efficient ground testing and flight test planning
  • ASTM Workmanship Standards:
    • American Society for Testing and Materials, an international standards organization that develops & publishes voluntary consensus technical standards for a wide range of materials, products, systems, and services.
  • IPC Workmanship Standards:
    • The Association Connecting Electronics Industries, a trade association that develops standards for the electronics manufacturing industry.
    - IPC-610: Acceptability of Electronic Assemblies, a visual acceptance standard.
    - IPC/WHMA-620: Requirements and Acceptance for Cable / Wire Harness Assemblies.
    - IPC J-STD-001: Requirements for Soldered Electrical and Electronic Assemblies.
    - In-house trainers for IPC J-STD-001 and IPC/WHMA-620
  • AS9100:
    • The international Quality Management System (QMS) standard for the Aviation, Space, and Defense Industry.
  • ISO 9001:2015:
    • The international standard that specifies requirements for a Quality Management System (QMS).

Aircraft Electrified Propulsion (AEP)

ESAero are subject matter experts in Hybrid and All Electric Propulsion

For 13 years, ESAero has served the Aircraft Electrified Propulsion needs of their customers

ESAero’s Key Capabilities in Aircraft Electric Propulsion:
  • “Clean Sheet” Electrified Aircraft Design
  • In-house Design, Analysis, and Simulation Tools
  • “ePHM” Prognostics and Health Monitoring
  • Battery Pack Design and Testing
  • Electric Motor DynoTesting
  • High Voltage BusDesign
  • Control Systems
  • Pathway to Certification
  • Electric Motor Design
  • Motor Controller Design
  • “Off the Shelf” Electric Air Vehicle Component Vendor Relationships and Sourcing
About ESAero

The ESAero mission is to specialize in cost-effective development of innovative and advanced concepts, with emphasis on simple honesty and a track record of commitment.

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