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Mace Aviation M5 prototype helicopter on the ground

Aerospace Composite & Metallic Structures Manufacturer

Defense-proven. Vertically integrated. Built for programs that can’t afford delays.

One Fabricator. Every Capability. Zero Handoffs.

Mace Aviation is an Arizona-based aerospace manufacturer with direct program experience at MD Helicopters, L3Harris, Lockheed Skunk Works, Stratolaunch, NAVAIR, and Scaled Composites. We fabricate composite structures, metallic assemblies, wiring harnesses, tooling, and FEA structural analysis in-house, on a single program. That vertical integration means fewer vendors, tighter schedules, and a fabrication partner who understands the engineering behind what they’re building.

  • Rocket icon — Mace Aviation aerospace capabilities
    Aerospace
  • Aircraft icon — Mace Aviation aviation capabilities
    Aviation
  • Automotive icon — Mace Aviation ground vehicle design
    Automotive
  • Electric vehicle icon — Mace Aviation ground vehicle capabilities
    EV
  • Military ground vehicles icon — Mace Aviation defense capabilities
    Defense
aerospace composite fabrication manufacturer

TELL US ABOUT YOUR PROJECT

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SERVICES LINEUP

  • 01. Design & Engineering

  • 02. Engineering

  • 03. Structural Analysis & FEA

  • 04. Composite Fabrication

  • 05. Tooling

  • 06. Rapid Prototyping

  • 07. Reverse Engineering

  • 08. Avionics & Wiring Harness

  • Mace Aviation aircraft design concept detail
  • Mace Aviation engineering drawing and analysis document
  • Mace Aviation CFD aerodynamic analysis simulation
  • Mace Aviation composite component in manufacturing
  • Mace Aviation composite tooling mold on workbench
  • Mace Aviation white composite prototype component
  • Mace Aviation reverse engineering 3D scan and point cloud model
  • Mace Aviation aircraft avionics wiring installation
  • 01. Design & Engineering

    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...
  • 02. Engineering

    Mace Aviation can provide engineering support across all portions of the design process. From simple hand calculations for initial layout to detailed Finite Element Analysis for sizing a wing spar, we possess the engineering skills necessary to efficiently and safely...
  • 03. Structural Analysis & FEA

    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...
  • 04. Composite Fabrication

    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...
  • 05. Tooling

    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...
  • 06. Rapid Prototyping

    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...
  • 07. Reverse Engineering

    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...
  • 08. Avionics & Wiring Harness

    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...
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NOTABLE CLIENTS

  • stratolaunch logo
  • lockheed martin logo
  • l3harris logo
  • scaled composites logo
  • blue origin logo
  • LTA logo
  • google x logo
  • vast logo
  • dillonaero logo
  • airbus logo
  • abl space systems logo
  • virgin galactic logo
  • galactic logo
  • ses logo
  • The marvin group logo
  • textron aviation logo
  • leidos logo
  • Robertson fuel systems logo
  • XP Services Logo
  • Ampaire Logo
  • MD Helicopters logo
TESTIMONIALS

You’re in good company

  • Cutting edge rapid prototyping, design, engineering and production. Mace Aviation has been our go to for the last 19 years.

    John Vandenberg

    Director | L3Harris

  • Mace Aviation is a unique company that can rapidly design and develop advanced composites for the aerospace industry and then produce these products at a very competitive price. The Mace team is both innovative and practical with decades of experience in the fixed and rotary wing market. They are smart, practical and affordable and very good to work with. Mace is a top notch team.

    Brad Pedersen

    CEO | MD Helicopters, LLC

Mace Aviation aircraft background image

Contact Us

Let's bring your product to life.

(480) 641-1359