UAV Components & Drone Manufacturing

Uncrewed System Components

As the largest U.S. producer of precision-engineered composite components for uncrewed systems, APEX brings decades of proven experience to programs involving Unmanned Aerial Vehicles (UAVs) and Unmanned Underwater Vehicles (UUVs). Our processes support programs at every stage, from prototype through low-rate and high-rate production.

With vertical integration across four U.S. manufacturing sites, APEX provides complete composite manufacturing solutions for the most advanced military and defense requirements.

Request a quote or contact us to learn how APEX Space & Defense can develop and manufacture superior unmanned system components for your application.

UAV and UUV Components We Design and Manufacture

Our UAV and UUV Unmanned solutions encompass a wide range of parts components and complete solutions, including final assembly and test. We've designed and manufactured parts for the smallest Group 1 drones to the largest Group 5 vehicles, including high altitude solar powered aircraft. Using superior-quality materials and advanced engineering capabilities, we deliver products customized to meet the unique requirements of the most demanding applications. Composite components we produce for UAVs and UUVs include:

Wing Assemblies and Flight Surfaces: Our wing assemblies and flight surfaces optimize the aerodynamics of UAVs and UUVs, including wings, ailerons, flaps, and other control surfaces.
Fuselage Assemblies: We make lightweight fuselage assemblies for UAVs/UUVs that achieve outstanding strength and structural integrity.
Payload Bays: From sensor arrays, communication modules, or specialized instrumentation, APEX's payload bays provide secure mounting solutions with optimal weight distribution.
Power and Battery Systems: We design and develop solutions for securing battery systems for UAV/UUV equipment.
Nose Cones: We design nose cones that reduce drag, improve airflow, and shield critical components from environmental factors. Our nose cones are available in various configurations to meet the specific needs of your UAVs and UUVs.
Environmental Control System (ECS) Components: For large vehicles such as Group 4 and 5 drones, APEX designs ECS solutions that help regulate temperature, humidity, and other environmental factors, including ducting, brackets, and more.
Ground Support Equipment (GSE): Our GSE solutions are crafted to protect and maintain the equipment used to operate your UAV/UUVs.

20+ Years Supporting UAV Systems Across All Groups

We have more than 20 years of experience designing and manufacturing composite components for uncrewed aerial systems across all five groups. Our work spans from Group 1 drones to Group 5 vehicles, including surveillance, high-altitude, long-endurance, solar-powered aircraft, and precision strike loitering munition systems.

Representative Programs by Group

Group 1: Eagle, Ghost, Raven, Switchblade 300, Wasp
Group 2: Lucy, Puma, Red Dragon, Switchblade 600, Vector AI
Group 3: Roadrunner, APID 60, OMAN
Group 4: SOAR
Group 5: Sunglider, Tern, Global Observer, Global Hawk, HAPS

Why Choose APEX for Composite Unmanned System Component Solutions?

At APEX, passion, innovation, and collaboration drive every solution we create. These values guide our team to deliver high-performance composite components with precision and reliability. In addition to manufacturing, we provide industry-best design, structural analysis, prototyping, testing, and materials development capabilities. With our integrated approach, along with industry-leading manufacturing equipment, we provide cutting-edge solutions for every stage of your product's development.

Manufacturing Capabilities

Wet Layup, Prepreg Layup, Compression Molding, and Filament Winding composites
Injection molding, additive manufacturing, assembly, machining, fabrication and welding
IRAD focus on new materials and cure processes

Engineering Capabilities

Design and structural analysis
Prototype and testing support
Requirements development
Materials and cure process development

Facilities and Equipment

High-speed filament winding systems
Lathes and 5-axis CNC milling machines
Large cure ovens (40’ x 20’) and autoclaves (15’ x 30’)
Patented metallic-to-composite bonding and testing
Proprietary materials, including RF applications
In-house mold and tool-making for faster prototyping and customization

Experience Across UAV / UUV Platforms and Mission Profiles

Vehicle Types: Fixed wing, rotorcraft, quadcopters, marine
Launch Types: CTOL, VTOL, STOL, launch tubes, rocket-assisted takeoff, rail, hand, bungee, and truck launches
Subsystems: Fuselages, wings, tails, fairings, control surfaces, payloads
Mission Profiles: ISR, loitering munitions, communications, supply delivery, munitions, electronic warfare, mapping/scanning, expeditionary operations