Carbon Fiber Unmanned Systems
LAND - SEA - AIR
Unmanned Vehicle Structures
Unmanned Vehicle Structures Element 6 Composites designs and manufactures custom UAV arms, chassis, and landing gear systems using advanced carbon fiber composite technology. Combining decades of experience in composites, structural design, and aerodynamics, we empower engineers to create lighter, stiffer, and more rugged carbon fiber structural components for unmanned vehicle applications. With projects ranging from multi-rotor hexagonal arm assemblies to fixed-wing fuselage structures, we have both the expertise and facilities to support your UAV development needs.
Complex Geometries
Unlike traditional materials that require machining away material, carbon fiber allows us to build optimized shell structures with fibers oriented precisely where strength is needed. This anisotropic design approach creates monocoque structures that maximize strength-to-weight ratios while enabling complex geometries impossible with metals or plastics. We specialize in UAV structural challenges including multi-rotor arm systems, central chassis assemblies, landing gear components, wing structures, and control surfaces. Our integrated design and manufacturing process ensures components are optimized for both performance and production efficiency. Below are examples of unmanned vehicle structures and components Element 6 Composites has helped design and produce.
Airship Gondola
Element 6 Composites worked with Remote Aerial Tripod Specialists Inc. to develop carbon fiber gondolas and tail fins for use in unmanned airships. Some of these parts are shown in the picture. By utilizing carbon fiber components, a significant weight savings was achieved.
Carbon fiber has also been used to create a sophisticated camera mount. These mounts are used for video or still photography to create stunning aerial photographs.
Decades of Experience
Element 6 Composites has worked with multiple companies to help develop and manufacture a variety of unmanned ground and air vehicles. Combining decades of experience in composites, structural design, and aerodynamics, Element 6 Composites supports customers in basic configuration design and analysis, component optimization, prototyping, and production manufacture.
With former and current projects ranging from military ground robotics to lighter than air vehicles to vertical takeoff and landing carbon fiber unmanned system, we have both the expertise and facilities to support your project. Below are a few examples of unmanned vehicles and components Element 6 Composites has helped design and/or produce.
AAI Corporation
Element 6 Composites worked with AAI to develop carbon fiber control vanes for a small vertical takeoff and landing UAV. Due to the application, high tolerances and manufacturing consistency needed to be maintained.
For more information regarding the production of carbon fiber UAVs or to request a custom quote for a project, we’re more than happy to help. Contact us and one of our experts will get back to you to discuss your needs. Thank you in advance for choosing Element 6 Composites.
International Climbing Machines
Element 6 Composites worked with International Climbing Machines [www.icm.cc] to develop a composite chassis for a revolutionary wall-climbing robot that was almost entirely made from carbon fiber. Using a combination of custom composite parts and CNC Dragonplate flat material, we constructed a robust yet lightweight carbon fiber UAV.
This carbon fiber robot is used in the nuclear industry, airplane inspection, wind turbine blade repair, and many other applications where the environment is either extremely harsh to humans, or the ability to climb sideways and upside down would result in drastically reduced labor time (as in the case of inspecting an airplane fuselage or wing). By replacing the original metal structure with a carbon fiber robot, ICM was able to greatly increase the robot’s performance and payload carrying ability.
Frequent Questions
Explain what services your provide
Element 6 Composites provides end-to-end composite engineering services tailored to meet the needs of industries that demand high performance and precision. Our capabilities include concept development, structural analysis, design optimization, and advanced manufacturing of composite structures. From creating custom carbon fiber parts to delivering turnkey composite assemblies, we handle every step with a focus on quality, reliability, and innovation. We also offer prototyping, testing, and consulting services to ensure every solution is engineered for strength, efficiency, and long-term durability.
What specific industries do you work with?
Our composite engineering services support a wide range of industries where advanced materials provide a distinct advantage. We design and manufacture custom carbon fiber parts and composite solutions for aerospace, automotive, defense, marine, energy, and industrial applications, among others. By leveraging the unique benefits of composites—lightweight strength, corrosion resistance, and design flexibility—we help our partners improve efficiency, reduce weight, and achieve breakthrough performance in even the most demanding environments.
Are you open to working on custom projects?
Yes—developing custom carbon fiber parts and unique composite solutions is central to what we do. Our team thrives on collaboration, working closely with clients to design, prototype, and manufacture one-of-a-kind products that meet precise technical and performance requirements. Whether you need a specialized component, a prototype for testing, or a full production run, our composite engineering services are built around flexibility and innovation to deliver solutions that exceed expectations.
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Carbon Fiber Specialists
