Mace Aviation reverse engineers aerospace parts and assemblies that exist physically but lack complete engineering definition. We work on everything from small fairings to entire aircraft. Using tools that range from precision micrometers to laser interferometry, we extract accurate geometry, resurface it in CATIA, and produce a complete 3D engineering package. That package can support design modification, new production tooling, or aging aircraft sustainment programs.
The need for aerospace reverse engineering arises most often in three situations. The first is legacy aircraft whose original drawings were never created, were lost, or are proprietary to an OEM that no longer supports the platform. The second is parts sourced from suppliers who have closed or are unwilling to provide data. The third is modifications to existing components where the baseline must be accurately captured before changes can be designed.
Mace Aviation specializes in all three. We have particular depth in fixedrotorcraft and aging defense platforms where airframe life extension is a program priority.
Aging defense platforms present a specific reverse engineering challenge: original OEM drawings are unavailable, the original manufacturer no longer supports the platform, or parts have gone obsolete with no direct replacement. Mace Aviation has direct experience with this problem.
Our reverse engineering engagements for legacy rotorcraft and defense systems go beyond delivering a CAD file. We capture the geometry, generate the engineering definition, design new tooling from that definition, and fabricate replacement or modified components — all within a single engagement. If you are managing airframe life extension or parts obsolescence for an aging defense system, we can take you from a physical part with no drawings to new hardware ready for installation.
Provide your material, your timeline, and your application. We'll give you a straight answer.
Reverse engineering engagements at Mace Aviation frequently continue beyond the CAD deliverable. Aerospace Design and Engineering provides engineering change and retrofit design built on the reverse-engineered geometry. Aerospace Composite Fabrication and Aerospace Metallic Structures cover production of replacement or modified hardware from the newly generated engineering definition, all within a single program engagement.
We reverse engineer composite and metallic aerospace components of almost any size or complexity, from small fairings and brackets to complete aircraft sections. Our work includes legacy military rotorcraft parts, weapon system structures, and sensor pod components that exist physically but lack complete engineering documentation.
Both. A Mace Aviation reverse engineering engagement can end with a complete 3D engineering package and drawings, or it can continue through tooling design, tool fabrication, and production of new parts from the reverse-engineered definition. All within a single engagement.
Yes. We have specific experience with legacy rotorcraft and defense platforms where original OEM definition is unavailable. If you are managing airframe life extension or parts obsolescence for an aging defense system, contact us to discuss the specifics.
Starts with an idea...ends with a product, the sky's the limit.
Cutting edge rapid prototyping, design, engineering and production. Mace Aviation has been our go to for the last 19 years.
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.
CEO | MD Helicopters, LLC
