Our full-spectrum aerospace capabilities cover the entire product lifecycle — from initial concept through structural analysis, fabrication, and final delivery. Each capability below has a dedicated page with full process details, FAQs, and program examples. Leverage our vertically integrated services for all your aerospace needs.
From concept sketch to detailed 3D assemblies, engineering drawings, and numerical control definition using CATIA V5 and SolidWorks. We provide structural design, CFD analysis, and engineering change packages for composite and metallic components. The engineer who designs it is in the same building as the fabricator who builds it.
Finite element analysis from component-level to full-aircraft FEM using Hypermesh, FEMAP, and NASTRAN — the same tools specified in defense and advanced development program contracts. We perform static, dynamic, fatigue, and composite laminate analysis. Unlike pure consultancies, we also fabricate the parts we analyze, so structural sizing directly informs material selection and layup design.
Structural aerospace composite fabrication from a dedicated, climate-controlled facility in Mesa, Arizona. We produce fuselage skins, fairings, control surfaces, sensor housings, and complex multi-piece assemblies using wet layup, prepreg, and vacuum infusion processes. Programs served include MD Helicopters, L3Harris, Lockheed Skunk Works, Stratolaunch, and Scaled Composites.
Aircraft-grade metallic structures fabricated in our dedicated metal shop — sheet metal forming, machined components, structural brackets and fittings, welded assemblies, and fully integrated metallic substructures in aluminum, titanium, steel, and stainless alloys. Because our composite and metallic shops share the same engineering team, integrated composite/metallic assemblies are managed in a single facility with no split-source risk.
Composite and metallic tooling designed and fabricated in-house — from low-cost foam prototype tools through carbon fiber and Invar high-temperature production tooling rated for 250°F and 350°F autoclave cure. Drill jigs, assembly fixtures, trim fixtures, and coordinate measurement templates. Tooling is designed by the same engineers who design the part, and built in the same shop that fabricates it.
Structural aerospace prototypes built from composite and metallic materials in days or weeks — not printed models, but real fabricated hardware using production-representative materials and processes. A Mace Aviation prototype can be structurally tested, qualified, and transitioned to production without a material or process change. We have delivered structural composite and metallic prototypes in under two weeks from drawing.
Reverse engineering for aerospace parts and assemblies that exist physically but lack complete engineering definition — lost OEM drawings, unsupported legacy platforms, or parts whose supplier has closed. We extract accurate geometry using precision measurement and laser interferometry, resurface in CATIA V5, and deliver a complete 3D engineering package. Engagements can continue through new tooling fabrication and production of replacement or modified hardware, all within a single program.
Avionics integration, aerospace wiring harness fabrication, and instrument panel design and build for defense and advanced development programs. MIL-SPEC wiring harness construction, 3D routing in CATIA and SolidWorks, connector termination, and certified installation. Our avionics team sits alongside our composite and metallic fabrication shops. Wiring infrastructure is designed and installed as part of the airframe build, not added at final assembly.
