Core Capabilities

ESAero provides engineering services in the following key areas:


  • 8,400 sq. ft. of Engineering Design Workspace
  • Subject Matter Experts in Hybrid/Electric Propulsion for Air Vehicles: "Brainernet" brainstorming and mapping process to outline vehicle requirements and sketch strawman configurations to adequately initiate the conceptual design process.
  • PANTHER – Propulsion Airframe iNTegration for Hybrid Electric Research design software created to address the highly-coupled Propulsion-Airframe-Thermal Inegration design space for electric aircraft.
  • TAO – Terminal Area Operations Tool for short field operations including powered lift for hybrid and electric.
  • Individualized in-house design codes for conceptual aircraft and component design.
  • SolidWorks 3D mechanical design software (Access to CATIA through Strategic Partners).
  • Reverse engineering methods.
  • Formal Technical and Marketing Presentations, ex. OV-1 per DoDAF V2.0, etc.


  • In-house optimized parametric codes (DoeTECH) for detailed mission performance, concept analysis and independent verification and validation (DoeTECH is a Visual Basic within Excel program).
  • Turbo Electric Distributed Propulsion (TeDP) and terminal area operations design and analysis tools developed in MATLAB and Visual Basic; with consideration for MDO.
  • ANSYS CFD Flo for Computational Fluid Dynamics
  • Altair Hyperworks
  • Noran Engineering NeiWorks for rapid structural design iterations during the design phase.
  • Noran Engineering NeiFEMAP and NeiNASTRAN for detailed structural analysis of final components and systems (compatible with MSC products).
  • Access to MSC NASTRAN and PATRAN through Strategic Partners.
  • Payload and Air Vehicle Mission Analysis.
  • Manufacturing Analysis, DFX


  • 20,100 sqft. Manufacturing and Integration Facilities
  • 800 sqft. Environmentally Controlled ESD Room / Systems Integration Lab
  • 1,000 sqft. Inventory and Integration Clean Room
  • Design for Manufacturing
  • LRIP Drone Production with Established Supply chain
  • K2 KG-3925 39” x 25” 3-axis CNC machine for light machining and rapid prototyping.
  • Composites molding and vacuum bag tooling.
  • General machine/mechanics shop equipment (Strong relationships with local shops)
  • ISO9001 Compliant Quality Management System (AS9100 Cert. planned for Fall 2017)


  • 6,400 sqft. Flight Testing Operations Facility
  • Instrumentation System Design and Integration w/ Prognostics and Health Management
  • Environmental Test Capability
  • On-airport location provides efficient ground testing and flight test planning.
  • Construction of component and system test-rigs as required.
  • Certified sUAS Pilots on staff with Use Permit for and Access to Oceano Airport


  • ESAero is capable and experienced at supporting niche engineering roles in support of a specific project or need. ESAero has served in this capacity for a number of customers.
  • Provide niche engineering support in any of the four main service areas.