Core Competencies

ESAero provides engineering services in the following key areas:

Design

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

Analysis

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

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

Testing

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:

UAV/UAS
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

View AEP Capabilities

View AEP Projects

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

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ECO-150

Additional Projects

ESAero has 20,000 Sq.Ft. dedicated to the manufacturing, integration, & testing of Unmanned Aerial Vehicles (UAVs) and Aircraft Electrified Propulsion (AEP)

ESAero provides engineering services in the following key areas:

Unmanned Aerial Vehicles

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

Aircraft Electrified Propulsion (AEP)

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

Full-Service Aerospace Engineering Firm Offering Aircraft Design, Manufacturing, Integration & Testing.