CAMX 2026 · Atlanta

Composite structures, from first sketch to flight hardware.

Design, analysis, tooling and build under one roof. Come and talk to the engineers who do the work.

PDF - 3.9 MB - 12 slides

AS9100D certified M4 Phoenix Technology Works

Full-vehicle composite prototype Build #2, 66 days start to finish

Georgia World Congress Center Building C, 285 Andrew Young International Blvd NW, Atlanta, GA

September 22-24, 2026

Composites Are In Our DNA

We are a composites shop with an engineering company attached, or the other way around depending on the day. The same people who run the analysis design the tooling, and the shop that builds the tool lays up the part. That is why programs come to us when the schedule is short and the structure is difficult.

  • 36ft Autoclave length
  • 65ft 5-axis gantry mill
  • 50+ Engineers and analysts
  • 33,500sq ft Across two shops

The equipment

Two facilities, 33,500 square feet, and the machines to take a composite structure from tooling board to finished assembly without leaving the building.

Autoclave with the door open in the M4 shop
Autoclave 5 ft x 36 ft
Walk-in composite curing oven
Curing oven 27 ft x 12 ft x 10 ft
Five-axis gantry mill machining a tooling board
5-axis gantry mill 65 ft x 18 ft x 10 ft
CNC trimming of a composite component
CNC trimming 5-axis gantry routers, 3-axis mill

What we make

Machined tooling board with a recessed mold cavity
Prototype and production tools
Machined fixture with a routed channel network
Fixtures and jigs
Four cured carbon fiber panels
Composite parts
Composite airframe on trestles in the hangar, an engineer alongside for scale
Assemblies and airframes

End to end, in house

Five disciplines that usually sit in five different companies, with a handoff and a rebuilt model between each one. We do all five, which is why a sizing decision can reach the shop floor the same week it is made.

Design

  • Composites and metallics
  • Structural
  • Mechanical
  • Aeronautical
  • Tooling
  • Jigs and fixtures
  • Assembly tools
  • DFM
  • DFA
  • GD&T
  • NX
  • SolidWorks
  • CATIA

Advanced analysis

  • Composites and metallics
  • FEA
  • Loads and dynamics
  • Mechanisms
  • CFD
  • Aeroelasticity
  • Flutter
  • Thermal analysis
  • Electronics cooling
  • Uncertainty quantification

Optimization

  • Multidisciplinary optimization
  • Weight reduction
  • Trade studies
  • Topology optimization
  • Laminate tailoring
  • Physics-based weight prediction
  • Surrogate models
  • System optimization

Manufacturing

  • Custom tooling
  • Composite molds
  • Jigs and fixtures
  • Prepreg
  • Wet layup
  • Infusion
  • Full-vehicle prototyping
  • Full-scale builds
  • Machining
  • Trimming
  • Finishing
  • Additive manufacturing

Testing

  • Sub-scale and full-scale structural test
  • Ground and flight
  • Wind tunnel
  • Strain gauges
  • Data acquisition
  • NDI
  • Coupon testing for allowables
  • Test-analysis correlation

Trusted by Industry Leaders

Ducommun Electra.aero JetZero Northrop Grumman Rock West Composites Safran U.S. Air Force Eviation GE Aviation Jacobs Engineering Maglev Aero Mayman Aerospace NASA Uber U.S. Navy Vector

Selected programs

Full-vehicle prototyping

Concept through to flight test support

Full-vehicle prototyping

Concept design, aero and structural simulation, tooling, metal and composite fabrication, wire harness, propulsion, flight controls and landing gear. Build #2 went start to finish in 66 days.

Composite inlet bell and exterior panels

Tooling through to finished part

Composite inlet bell and exterior panels

Conceptual CAD taken to manufacturing-ready tooling, 5-axis machined tooling boards, layup to customer specification, then demold, inspect and CNC trim.

Unmanned fixed-wing demonstrators

With NASA Armstrong

Unmanned fixed-wing demonstrators

Two 12-ft wingspan demonstrators in foam-core fiberglass and carbon fiber, strain gauges built into the wing, static bend test and wind tunnel validation, then flight test with in-flight strain data.

eVTOL structural design

Uber eCRM-001 and eCRM-002

eVTOL structural design

Physics-based sizing and weight trades for tilt-rotor and lift-plus-cruise configurations, with automated FEM generation and vehicle-level structural optimization.

Propulsion and launch vehicle

Structures, thermal and flow

Propulsion and launch vehicle

Rocket injector stress and conjugate heat transfer, feed-system flow distribution, random vibration of propulsion plumbing, and composite interstage tooling and fabrication.

Unsteady loading on store trajectories

Air Force Research Laboratory

Unsteady loading on store trajectories

A computational tool combining wind tunnel testing with CFD to screen store separation characteristics, cutting analysis time and focusing detailed testing on the higher-risk configurations.

Take the deck with you

M4 Engineering capabilities deck: the facilities, the equipment list and the programs behind them.