UK Drone Manufacturing

Why the Drone Sector Needs Advanced Composites

As UAV and drone platforms evolve, performance increasingly depends on lightweight, durable, and repeatable composite structures.

CCP Gransden’s mix of thermoset and thermoplastic technologies, high-rate automation, and aerospace-grade quality systems (AS9100, ADS SC21 GOLD) offers a strong UK manufacturing partner for this growing sector.


Bridging the Gap from Development to High-Rate Production

Many drone projects in the UK reach successful prototype or low-rate builds but face challenges scaling to consistent, repeatable manufacture. CCP Gransden bridges this gap by combining aerospace-grade process control with automation and tooling that supports genuine production volume — bringing proven R&D concepts into high-rate, real-world delivery.

 

Proven Capability

  • Extensive in-house technologies – one of the UK’s broadest ranges of composite manufacturing processes.

  • Aerospace-qualified materials and systems – PEEK, PPS, PEI, and epoxy-based composites meeting FST and low-VOC standards.

  • High-rate production cell featuring:

    • 11 000 kN Engel press with integrated oil, water, and electric tool heating

    • 6-axis robot and 56-zone IR oven

    • Inline data capture and automated QC

    • Cycle times of 2–5 minutes

  • Capacity for up to 100 000 parts per year.

  • Supporting capability in-house; CNC, waterjet, clean room, paint booth, etc. 


Core Technologies for Drone Applications

Thermoset Processes

  • High-Pressure RTM (HPRTM) – rapid production of structural components in < 3 minutes.

  • Compression Moulding (SMC) – carbon-fibre reinforced materials enabling ribs, bosses, and co-moulded inserts.

  • Hybrid SMC Structures – co-moulded continuous-fibre skeletons and foam cores for targeted stiffness and weight reduction.

Thermoplastic Processes

  • Thermoforming – continuous-fibre laminates (PEEK, PPS, PEI, PA12) formed in as little as 1 minute.

  • Overmoulding – single-stage bonding of reinforced laminates with injection-moulded plastics for integrated parts.

  • Recyclable Composites – self-reinforced polymers and thermoplastic recyclate for sustainable production.

Hybrid & Novel Technologies

  • Clear-melt and Varysoft systems – multi-component processes delivering scratch-resistant or soft-touch surfaces for housings.

  • 7-axis filament winding – for tubes, spars, and fuselage structures requiring high stiffness-to-weight ratios.

Example UAV & Drone Components

  • Airframes and fuselage shells

  • Launch tubes and canisters

  • Wing spars and control surfaces

  • Payload bays and equipment housings

  • Mounting brackets and structural frames


 

Building Scalable, Sovereign Capability

As demand grows for drones and unmanned systems across defence and aerospace, scalable UK-based manufacturing is increasingly important. CCP Gransden supports this need, providing repeatable, automated production within a fully traceable, aerospace-grade environment.

By bringing thermoset, thermoplastic, and hybrid processes together under one roof, CCP Gransden enables OEMs and Tier 1s to produce high-quality parts rapidly and reliably, strengthening the UK’s sovereign supply chain.

This combination of automation, flexibility, and UK-based capability positions CCP Gransden as a reliable manufacturing partner for the next generation of unmanned platforms.

To explore how CCP Gransden can support your programme, please get in touch to arrange a meeting.

Back to news