Flyber is a developer of robust carbon-fiber composite propeller solutions which enable optimal aerodynamic performance in military and government unmanned aerial vehicles (UAVs) and urban air mobility (UAM) systems.
Rowan Carstensen, CEO and co-founder at Flyber.
In this exclusive Q&A, DA sat down with Rowan Carstensen, the CEO and co-founder of Flyber, to discuss Flyber’s product innovation, manufacturing capabilities, and ambitious goals in both commercial and defense applications.
Rowan, can you explain what Flyber does in practical terms?
At Flyber, we design, engineer, and manufacture propellers for UAVs, serving both commercial and defense sectors. Our products include ready-to-ship UAV propellers and bespoke rotor blades for UAM projects. These are built using advanced carbon-fiber composites for optimal stiffness, strength, thrust efficiency, and low noise.
What makes your propellers different from off-the-shelf alternatives?
Flyber’s propellers are developed using proprietary manufacturing methods combined with engineering precision. Unlike generic off-the-shelf products, our blades deliver better performance in thrust-to-mass ratio, reduced noise, and improved durability, as well as being engineered for scalability and regulatory compliance. This allows our customers to easily switch from current suppliers, often based in high-risk geopolitical areas.
Who are Flyber’s main customers?
We support a wide range of defense and commercial applications, including military UAVs, logistics drones, surveillance platforms, and UAM systems like air taxis. Our off-the-shelf propellers suit mission-critical needs, while our bespoke capabilities support bespoke mission profiles, such as ISR, heavy payload lifting, or acoustic stealth.
Can you walk us through Flyber’s engineering process?
Our in-house team covers the entire development workflow. We begin with designing propellers using aerospace-grade CAD and design-for-manufacturing principles, ensuring that all performance priorities for our customers are met. This stage is critical, as it defines the targets and scope.
Next, we conduct simulations using CFD analysis, load modeling, and, where possible, real-flight data. We are also working on establishing in-house testing capabilities in the near future.
Finally, manufacturing is carried out under quality-controlled automation, ensuring traceability and repeatable performance. This approach guarantees not only consistent quality but also favorable production economics for our customers.
All products are made in the UK, offering secure supply chains and fast lead times.
How does your automotive and motorsport background influence the company?
My experience taught me the importance of weight optimization and manufacturing precision. At Flyber, that translates into designing propellers where every gram matters, ensuring they are production-ready and mission reliable. It is about bridging high-performance engineering with scalable manufacturing and offering tailored, best-in-class service to our customers.
How does Flyber support sustainability goals?
Our composite propellers reduce aircraft weight and improve efficiency, enabling longer flight times and lower energy consumption. Our UK-based production also minimizes geopolitical risks and reduces waste across the supply chain. We are working on some ‘secret’ sustainability initiatives we can hopefully share with you soon.
What certifications and quality protocols do you follow?
All products undergo rigorous testing to meet aerospace, defense, and civil aviation standards. Flyber is actively pursuing ISO 9001 and Cyber Essentials certification, reinforcing its commitment to quality and security.
How does Flyber balance innovation with manufacturability at scale?
Our mission is driven by scalable innovation. We only develop designs that can be reliably mass-produced without sacrificing performance. The team’s knowledge and internal IP means we can engineer incredibly complex shapes that deliver optimal aircraft and propeller performance.
Our proprietary automation, digital QA, and tooling systems ensure high volumes without whilst maintaining precision and schedule flexibility.
What is next for Flyber in the upcoming year?
We are expanding our pilot programs with strategic partners, boosting production capacity, growing our engineering team and preparing to commercialize fully both off-the-shelf and bespoke propeller lines. We are ready to support disruptive mission profiles with scalable precision, whether you are deploying UAV fleets or designing UAM systems .
With motorsport-inspired design, aerospace-grade precision, and secure UK-based manufacturing, Flyber is set to elevate UAV performance across both defense and commercial domains.
Thank you so much for your time. It has been a pleasure talking with Flyber, and we look forward to following your continued advancements of propeller solutions in the defense industry.
