Custom UAV Design & Development. Engineered to fly.
AVIOX develops custom unmanned aircraft from early feasibility through aerodynamics, CAD and manufacturing-oriented detailed design. Experience includes fixed-wing UAVs, flying wings, VTOL aircraft, multirotors and aircraft optimized for FDM 3D printing or CFRP construction.
Aircraft development without unnecessary overhead.
Engineering depth scales with project risk and maturity—from preliminary sizing and flight stability to detailed CAD, manufacturing integration and iterative prototype support.
01
Mission & preliminary aircraft design
Mission analysis, requirements, configuration selection, preliminary sizing and technical feasibility.
02
Aerodynamics, stability & performance
Airfoils, wing and tail sizing, flight-stability analysis, controllability, range, endurance and aerodynamic optimization.
03
CAD & aircraft geometry
Freeform and surface CAD, complete outer geometry, aerodynamic transitions, fairings and STEP-ready models.
04
Propulsion, energy & systems
Propeller or EDF sizing, motors, batteries, energy assessment, avionics, payload packaging and system integration.
05
FDM, CFRP & manufacturing design
Design for FDM 3D printing, CFRP composites, CNC, wood and hybrid construction, including modularization, tooling and assembly.
06
Prototype, testing & iteration
Build and integration support, test planning, flight-test evaluation, troubleshooting, redesign and technology demonstrators.
A large FDM flying wing engineered for practical UAV development.
AVIOX has been developing Vulfguard's 2.4 m EDF flying wing since September 2024. The aircraft combines a predominantly FDM-printed structure with CFRP reinforcement and has been refined through practical manufacturing and flight experience.
Each phase is quoted separately. Exact scope, fixed price and schedule for the next phase are defined only once the previous phase has produced enough technical information for a reliable estimate.
PHASE 0
€250–9001–3 weeks
Feasibility & Project Definition
Determine whether the concept is technically realistic and define a viable development direction.
Mission and requirement analysis
Preliminary sizing, MTOW and payload estimates
Basic performance, range and endurance estimates
Preliminary propulsion and energy sizing
Configuration evaluation
Major technical risks, constraints and recommended development approach
PHASE 1
€250–1,0001–3 weeks
Aerodynamic & Physical Layout
Define the main aerodynamic configuration, dimensions, stability and system layout.
Wing, airfoil and tail sizing
Preliminary fuselage and overall geometry
Aerodynamic performance analysis
Stability and controllability analysis
CG and mass distribution
Propulsion and energy sizing
Preliminary component and payload packaging
Definition of main aircraft dimensions and configuration
PHASE 2
Approx. €250–1,2001–3 weeks
General Outer Surface CAD Design
Convert the defined aircraft configuration into a complete external 3D geometry.
Fuselage, wing and tail surfaces
Aerodynamic transitions and fairings
CAD basis for detailed design, CFD, prototyping or tooling
STEP files and complete external aircraft geometry
PHASE 3
€250–7,000+Approx. 2–20 weeks
Detailed Design
Develop the external geometry into a manufacturable and assembly-ready aircraft design.
Internal wing and fuselage structure: spars, ribs, shells and connections
Detachable wing or fuselage sections
Servo mounts, hinges and control linkages
Propulsion, battery, payload and avionics integration
Landing gear, hatches, mounting hardware and access provisions
Manufacturing and assembly design
Optimization for FDM, composites, CNC, wood or hybrid construction
Production files, drawings, BOMs and assembly information where required
For long-term programs, phases can be repeated in iterative loops with static prototypes, flying prototypes and technology demonstrators between design cycles. AVIOX can support those build, test and redesign loops as well.
Phase 0 is optional when requirements are already sufficiently defined; high-risk or unusual concepts benefit most from an early feasibility phase.
Start a UAV project
Have an aircraft concept that needs engineering?
Send the mission requirements, constraints and current development status. AVIOX can assess the next useful engineering step.
