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UAV FLAP & AILERON - Resin Transfer Molding

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AAI Shadow 200 Aileron Assembly Detail
AAI Shadow 200 Aileron Assembly Detail
AAI Shadow 200 Flap Assembly
AAI Shadow 200 Flap Assembly
AAI Shadow 200
AAI Shadow 200

Aircraft photos courtesy of AAI Corporation

The AAI Corporation Shadow® 200 unmanned aerial vehicle (UAV) is used by the United States Army and Marine Corps to provide brigade commanders with real-time battlefield footage that allows them to implement the right decisions at critical moments. When Fiber Dynamics, Inc. was approached to provide wing flaps and ailerons that control the Shadow® 200 while in-flight, needless to say we set our technological wherewithal and brainpower to the test. The results we arrived at were, to say the least, impressive.

By wielding CNC ply cutting onto carbon fiber, we developed wing flaps and ailerons with respective lengths of 59” and 32”, and unobtrusive widths of 7.5” and 5.5”. We also built a foam core using “one-shot,” matched-die resin transfer molding (RTM) and the out-of-autoclave process, which allowed for seamless integration with the outer structure. We finished the job by applying prime and top-coat finish with a paint-job of gray with stenciled black lettering. With 2 flaps and 2 ailerons per ship set to supply each UAV, we were able to produce an upwards total of 600 such ship sets.

Just as Shadow® 200 UAVs provide today’s commanders with the agility and finesse to make real-time decisions on the modern battlefield, our wing flaps and ailerons provide the Shadow® 200 with the necessary agility and aerial flexibility in carrying out its crucial mission. For additional information contact Fiber Dynamics today.

Project Highlights

Product Description
  • Fiber Dynamics, Inc. manufactured this UAV flap & aileron ship set which consisted of 2 flaps & 2 ailerons per ship set.
Capabilities Applied/Processes Primary:
"One Shot" Matched Die Resin Transfer Molding (RTM)
  • Out-of-Autoclave Process
  • Complex Hollow-Cavity Component
  • CNC Fabrication of Foam Core
  • Installation of External Fittings
  • Prime & Paint
  • Stenciling
Overall UAV Flap & Aileron Ship Set Dimensions
  • Length: 59" & 32"
  • Width: 7.5" & 5.5"
Material Used
  • Carbon Fiber, Foam Core
Material Finish
  • Prime & Top Coat
  • Integrated structure with internally captured metal fittings and foam core
Industry for Use
  • UAV (Unmanned Aerial Vehicle)
  • 600+ Ship Sets (2,400+ Pieces)
Delivery Location
  • United States
Standards Met
  • Customer supplied print, 2D CAD Drawing
Product Name
  • UAV Flap & Aileron Ship Sets

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Fiber Dynamics, Inc. | Composite Solutions Since 1990