Custom Composite Manufacturing for Military & Defense Projects

Fibreworks Composites is a specialist U.S.-based provider of custom composite design-to-spec and build-to-print manufacturing services for military, defense and aerospace OEMs. The company produces individual parts and fully finished assemblies for a wide range of programs including tactical UAS, military ground platforms and deployable communications systems.

The Fibreworks Group combines the engineering, machining and tooling capabilities of Fibreworks Composites with the manufacturing, certification and quality control resources of sister company Composite Factory. This vertically integrated structure provides a one-stop shop for the entire project lifecycle.

Fibreworks Composites is an approved parts supplier to a wide range of leading defense primes, including:

Anduril
Lockheed Martin
Northrop Grumman
General Dynamics
Bell Textron
Archer
Shield AI

Fibreworks Composites and build-to-print manufacturing

Composite Manufacturing for Military & Defense Projects

Design-to-spec and build-to-print composite structures for mission-critical platforms & equipment

Fibreworks provides cutting-edge composite manufacturing capabilities for defense programs to suit any component size or production requirements, supporting initial development through to low-rate or mass production.

The company’s state-of-the-art facilities provide vertically-integrated capabilities with minimal outsourcing, reducing risk to clients while enabling a competitive cost structure. These facilities are certified to ISO 9001:2015 and utilize an AS9100D-compliant QMS, ensuring the utmost in quality for all components.

All production levels are supported, enabling you to scale confidently while retaining the same manufacturing partner:

Prototype (1 – 5 units) – rapid delivery of test-ready components and assemblies
Low-Rate Production (5–100 units) – seamless transition from prototyping through to production
Mass Production (100s or 1000s) – proven rate production for full aerostructures & other assemblies

Ground Vehicles & UGVs

Fibreworks provides engineered composite structures for military ground vehicles, UGVs and other tactical land platforms. Its vertically integrated capabilities ensure seamless transition from concept to production, giving defense OEMs a single partner for lightweight components that must accommodate sensors, electronics and structural interfaces and perform reliably under challenging real-world battlefield conditions.

Component capabilities include:

Structural composite roof modules
Military-grade exterior body panels and fairings
Sensor pods
Roof racks
Fully enclosed electronics and equipment housings

Programs can begin with an early-stage concept or a finished design, and Fibreworks offers scalable production capacity from prototype and validation builds through to low-rate and fleet-level manufacture.

Design and engineering support includes full design-for-manufacture (DFM) collaboration and comprehensive structural analysis using load inputs and FEA.

Tactical SATCOM Systems

Fibreworks develops and manufactures lightweight composite structures for mission-critical SATCOM systems, offering tight tolerances, rugged reliability and repeatable performance at scale. These solutions are designed to address demanding RF, structural, environmental and dimensional requirements, and production can be scaled from initial prototypes to thousands of assemblies.

Satellite Reflectors – Tactical & Man-Packable Systems

Fibreworks manufactures modular composite reflectors and components for tactical communications systems that must be transported, assembled and deployed in the field. Customer-selectable petal counts allow packed size and weight to be optimized according to mission requirements. Solutions are available for X, Ku and Ka-band systems operating with GEO, MEO, LEO and HEO satellite networks.

Capabilities include:

Modular reflector systems from 1 to 5 meters in diameter
Carbon composite booms
Composite petals, hubs and backing structures
Multicomponent reflector assemblies
Raw carbon, coated reflective or fully painted finishes
Deployment-ready finished assemblies with latches

Satellite Reflectors – Ground Station & Earth Gateway

Fibreworks also provides composite solutions for permanent SATCOM ground stations and earth gateways, with specialist components designed for integration into larger fixed-site communications systems.

The company can manufacture high-tolerance sub-reflectors, composite strut systems and large-format reflector petals. Fibreworks also produces the tooling and associated composite components required for full ground station integration.

Ruggedized Carbon Fiber Cases

Fibreworks manufactures lightweight carbon-fiber cases for transporting and protecting tactical communications equipment. Designs can be developed around customer requirements or produced from supplied drawings, with configurations optimized for rapid deployment in demanding operational environments.

Cases can be provided through build-to-specification or build-to-print programs and supplied as fully assembled, integration-ready units. Fibreworks also conducts in-house drop testing and validation to verify each design against the relevant transport and operational requirements.

Manned Aircraft

Fibreworks provides aerospace-grade composite engineering and manufacturing for manned military aircraft and other defense aviation programs. These solutions are precision-engineered to meet demanding performance, durability, environmental and airworthiness requirements. Programs can progress from full engineering design through to repeatable large-scale production.

Component capabilities include:

Crew and cabin interior structures
Interior consoles, headers and doors
Secondary-structure fairings
Internal elements of mass
Cargo-bay components
Auxiliary structures
Fully finished and painted assemblies

Components can be manufactured from carbon fiber or glass fiber, including sandwich-panel constructions using Rohacell, PVC, honeycomb or Plascore cores. Metallic, glass-fiber and phenolic inserts are also available.