Fabrication
HIGH SPEED AND HIGH QUALITY: The fabrication shop at Scaled Composites, LLC is known for its high-speed and high-quality work. Extensive use of composite materials allows the fastest possible prototype fabrication - prototypes that are very light, strong, simple and cost effective. We use many fabrication techniques such as filament winding and large scale, integrated co-cured components to generate very efficient structure. Many applications involve low-temperature composites that allow inexpensive and simple tooling. When requirements demand, Scaled has the facilities and experience to work with higher temperature materials. We routinely build autoclaved parts with 350°F cure and 400°F service temperature.
MULTI-DISCIPLINED: While everyone in the shop (and in Engineering too!) is a composites fabricator, there are many other areas of expertise. We have experts in the areas of flight control fabrication and integration, avionics and electrical installation, as well as mechanical system integration. Included in our facilities are a machine shop, welding shop, sheet metal shop, and painting booth. In addition, several of our shop employees are dedicated to maintaining the aircraft for our flight test programs and for other company use.
From rockets to radio-controlled airplanes, the shop personnel at Scaled have the tools and experience necessary to make our customers' projects a success.
MULTI-DISCIPLINED: While everyone in the shop (and in Engineering too!) is a composites fabricator, there are many other areas of expertise. We have experts in the areas of flight control fabrication and integration, avionics and electrical installation, as well as mechanical system integration. Included in our facilities are a machine shop, welding shop, sheet metal shop, and painting booth. In addition, several of our shop employees are dedicated to maintaining the aircraft for our flight test programs and for other company use.
From rockets to radio-controlled airplanes, the shop personnel at Scaled have the tools and experience necessary to make our customers' projects a success.


Founded in 1982 by Burt Rutan, Scaled has broad experience in air vehicle design, tooling and manufacturing, specialty composite structure design, analysis and fabrication, and developmental flight tests of air and space vehicles.
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Model 97 is a two-place, side-by-side airplane of the 300 lb empty weight class. It has a slightly swept-back canard forward and swept back wings with winglets at the tips.
A subscale version of an eleven-place, twin turboprop, high-performance business aircraft developed for Beech Aircraft Corporation.
The Model 133-4.62 ATTT proof-of-concept demonstrator is a 62% scaled version of an airplane designed to challenging STOL and long range requirements.
The all-composite Triumph, an 8,500 lb, pressurized 8-place business aircraft, was designed around the brand-new, never flown, Williams FJ-44 turbofan engine.
Scaled did the structural design, tooling, fabrication, and static testing of an 85 ft span and a 108 ft span rigid sail/airfoil for the America’s Cup Challenge Race.
The ARES, Scaled Model 151, was designed initially in response to a U.S. Army request for a Low Cost Battlefield Attack Aircraft (LCBAA).
The Advanced Engineering Staff of General Motors designed a technology demonstration vehicle called the Ultralite, an automobile with interior room capable of seating four full size adults, and with excellent visibility, handling, performance, emissions and fuel consumption.
The Raptor Demonstrator high-altitude, long endurance, unmanned aerial vehicle (UAV) program was conducted under a contract from Lawrence Livermore National Laboratory to Scaled Composites, LLC.
In early 1993, Jim Rice and Tom Stark of the fledgling VisionAire Corporation visited Scaled with conceptual designs for a new single-engine business jet.
Walled Lake, Michigan, June 23, 1997 -- Williams International today announced that its all-composite, turbofan- powered "V-JET II" light aircraft is on schedule for its July 31 fly-in and follow-on demonstration flights and exhibition at the Experimental Aircraft Association (EAA) convention at Oshkosh, July 30 to August 5, 1997.
Proteus is a twin-turbofan, high-altitude, multi-mission aircraft powered by Williams International FJ44-2E engines.
The Model 309 is a proof-of-concept aircraft built for Adam Aircraft Industries.
The GlobalFlyer is a single seat, turbofan powered airplane designed to fly around the world nonstop, unrefueled, with a solo pilot.
SpaceShipOne, the first private manned spacecraft, is a three-place, high-altitude research rocket.
White Knight is a three-place, high-altitude, flexible and capable research aircraft.
The Model 326 aircraft (or Pegasus X-47A) is an unmanned aerial vehicle built for Northrop Grumman.
SpaceShipTwo will be powered by a unique hybrid rocket motor, which is currently under development.
WhiteKnightTwo, or Eve, is the mothership and launch platform for SpaceShipTwo.
