Custom UAS solutions from concept to flight-tested reality.
When off-the-shelf platforms can’t meet your requirements, Flightstack’s design engineering team delivers custom solutions. From initial scoping to field validation, we turn specialized requirements into flight-ready prototypes — fast.
Flightstack Special Projects
Flightstack Special Projects is our division for UAS rapid prototyping, design engineering, and specialized solutions. We work at the intersection of innovation and execution — moving fast without compromising quality.
Our team consists of FPV pilots, mechanical engineers, and systems integrators who understand flight dynamics, component integration, and real-world operational constraints.
Capabilities
Custom Carbon Fiber Frame Design
- Mission-specific frame geometry and sizing
- Carbon fiber layup design and optimization
- Structural analysis and weight optimization
- Modular designs for field serviceability
- Racing, freestyle, and commercial frame variants
Product Packaging Design
- Professional branding and visual identity
- Protective packaging for shipping and retail
- Retail-ready presentation and unboxing experience
- Custom inserts and component organization
- Brand consistency across product lines
Rapid Prototyping
- 3D design and CAD modeling
- FDM and resin 3D printing for quick iterations
- Precision laser cutting
- CNC machining for production-quality components
- Quick-turn manufacturing for fast development cycles
Design Engineering
- Custom airframe design and analysis
- Systems integration and component selection
- Payload interfaces and mounting solutions
- Structural analysis and stress testing
- Weight optimization and performance modeling
Solutions Scoping
- Requirements analysis and feasibility assessment
- Trade studies and design alternatives
- Performance modeling and simulation
- Risk assessment and mitigation planning
- Project planning and timeline development
Testing & Validation
- Bench testing and component validation
- Flight testing and performance verification
- Environmental testing (temperature, vibration, moisture)
- Field testing in operational environments
- Documentation and test reports
Manufacturing Equipment
Carbon Fiber Fabrication
- Custom carbon fiber frame layup and fabrication
- Precision cutting and shaping of carbon fiber sheets
- Structural optimization for weight and strength
- Racing, freestyle, and commercial frame variants
3D Printing
- FDM printing for functional prototypes and structural components
- Resin printing for high-detail parts and complex geometries
- Material options: PLA, PETG, ABS, TPU, nylon, engineering resins
Laser Cutting
- Precision cutting for carbon fiber, G10, acrylic, and composite materials
- Tight tolerances for production-quality components
- Fast turnaround for design iterations
CNC Machining
- Multi-axis machining for complex parts
- Aluminum, titanium, and composite materials
- Production-quality surface finish
Packaging Design
- Professional product packaging and branding
- Protective packaging for shipping and retail
- Custom inserts and component organization
- Retail-ready presentation and unboxing experience
Our Process
Discovery & Scoping
We work with you to understand your mission requirements, constraints, and success criteria.
Concept Design
We develop initial design concepts with performance modeling and feasibility analysis.
Rapid Prototyping
We build and test prototypes quickly, iterating based on test results and feedback.
Testing & Validation
We validate performance through bench testing, flight testing, and field operations.
Refinement
We refine the design based on test data and operational feedback.
Handover
We deliver complete documentation, CAD files, build instructions, and technical support for production or deployment.
What We Design
Custom Airframes
- Mission-specific frame geometry and sizing
- Structural optimization for payload capacity
- Modular designs for field serviceability
- Rapid-replacement component interfaces
Payload Integration
- Custom mounting solutions for sensors and equipment
- Power distribution and data interfaces
- Vibration isolation and stabilization
- Environmental protection (weather, dust, impact)
Specialized Capabilities
- Tactical integration: droppers, spotlights, glass breaks
- Long-endurance power systems
- Redundant flight systems for critical operations
- Mesh networking and communications relay
- Custom ground control and mission planning systems
Small-Batch Production
- Low-volume production runs (10-100 units)
- Production tooling and documentation
- Quality control and testing protocols
- Supply chain setup for ongoing production
Who We Serve
Defense and National Security
Custom solutions for specialized requirements that commercial platforms can’t address.
Public Safety Agencies
Tailored platforms and capabilities for unique operational environments and mission profiles.
Research Institutions
Experimental platforms and sensor integration for R&D programs.
Commercial Innovators
New product development, proof-of-concept work, and pilot production.
Why Flightstack Special Projects
Speed
We prototype and iterate faster than traditional engineering firms.
Expertise
Our team lives and breathes FPV and UAS technology — we understand flight dynamics, integration challenges, and operational realities.
Flexibility
We work on fixed-price projects, time-and-materials engagements, or retainer relationships.
Partnership
We become an extension of your team, providing ongoing support and iteration.
Services Summary
- Custom UAS platform design
- Rapid prototyping and iteration
- CAD modeling and design engineering
- Solutions scoping and feasibility studies
- Payload integration and custom interfaces
- Testing and validation (bench, flight, field)
- Manufacturing and small-batch production
- Technical documentation and handover
- Ongoing technical support
Start the Conversation
Have a specialized requirement that off-the-shelf platforms can’t meet? Let’s talk about how we can design and build a custom solution.
📧 Flightstack Special Projects:
commercial@flightstack.aiFrom concept to flight test in weeks, not months.
Flightstack Special Projects delivers rapid prototyping without compromising quality or performance.