Hawthorn Aero maintains a robust suite of inspection, manufacturing, and engineering capabilities to support advanced composite production. Our 1,200-square-foot Quality Control and Characterization Lab is equipped with state-of-the-art inspection and metrology systems, including four Virtek Iris 3-D dual-head laser projection systems (configured as two paired sets), a Dolphitech DolphiCam 2 non-destructive inspection system, and a Creaform MetraSCAN Optical CMM scanning system.

Our machining, cutting, and fabrication capabilities include a Thermwood 5-axis CNC router with a 5’ x 10’ x 4’ work envelope, a 4-axis high-speed router (8’ x 6’ x 14”), and multiple cutting platforms such as an Autometrix fabric cutting table (6’ x 22’) and an Earl automated table cutter (75” x 180”). Additionally, we operate six infusion stations and five infusion vessels to support high-throughput composite manufacturing.

In additive manufacturing, Hawthorn Aero utilizes a Modix Everest IDEX 3D printer with a 1m x 1m x 2m build volume, alongside a Formlabs Form 4 SLA printer and Bambu Lab systems, which are deployed as production-grade assets for rapid prototyping and tooling support.

Our digital engineering environment includes CATIA V5, Fibersim composite design software, SolidWorks, Autometrix PatternSmith nesting software, and EastmanPRO software for cutting operations, enabling efficient and precise design-to-production workflows.

These tools support a wide range of core technical capabilities, including structural composite part manufacturing, complex and trapped-geometry solutions, and unitized composite structures. Hawthorn Aero specializes in cost-optimized composite engineering, press-cured parts, Resin Transfer Molding (RTM), and Vacuum-Assisted RTM (VARTM). We also provide comprehensive tooling and ply design for scalable production, advanced inspection and non-destructive evaluation (NDI), and rapid prototyping solutions to support both tooling and production needs.