Thermoformed composite airframes for unmanned aerial systems in series production
EXTALON Industries GmbH
Hagen (North Rhine-Westphalia)New on Amplifa
About EXTALON Industries
EXTALON Industries GmbH develops and manufactures flight-capable airframe structures for unmanned aerial systems (UAV) in Hagen. At the core of production is the EXTALON platform: a scalable aviation framework with swept-wing geometry, large internal volume and a lightweight composite structure manufactured using a patented thermoforming process. Production is organized as an industrial series-capable operation; a complete set of airframe shells leaves the forming line in under three minutes, with cycle time determined by the machine. The platform offers defined mechanical and electrical interfaces through which customer-specific systems can be integrated, as well as dedicated tooling for program-specific configurations. Platform key figures: 2.40 m wingspan, 25 kg maximum take-off mass, 5 kg payload and 200 km range. The company offers evaluation, integration and series production of airframe shells from a single source.
- Site
- Hagen
- Processes
- Thermoforming (thermoforming of composite structure / airframe shells, patented process, cycle time, Aviation platform manufacturing / integration of customer-specific systems (mechanical &, Engineering / platform design (EXTALON airframe platform, swept-wing architecture, dedicated, Aviation framework / airframe production (EXTALON platform), Thermoforming of composite structures (patented process), Integration of customer-specific systems via modular interfaces, Series production of airframe shells, Evaluation and integration for UAV programs
- Materials
- Composite (thermoformed composite structure), Thermoformed composite structure, Thermoforming
- Certificates
- ISO 9001
- Industries
- Unmanned systems / drones (UAV), Aerospace, Composite material production
- 01
Engineering / platform design (EXTALON, complete tooling design)
- 02
Thermoforming of the composite structure
- 03
Series production of airframe shells
- 04
Integration of customer-specific systems via modular interfaces
Materials & Processes
Thermoformed composite structure
Lightweight airframe structure of the EXTALON platform, manufactured using a patented thermoforming process.
Thermoforming
Industrial, series-capable forming process with a cycle time of under three minutes per shell set.
Sites
Hagen
DEProduction and administration
- Part weight / size
- Airframe: 2.40 m wingspan, 25 kg MTOW
- Lot size
- Series production
- Materials
- Composite (composite structure)
- Thermoforming line / forming line
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Thermoforming (thermoforming of composite structure / airframe shells, patented process, cycle timePlastics | – | – | – | Series production (series-capable) | Composite (thermoformed composite structure) |
| Aviation platform manufacturing / integration of customer-specific systems (mechanical &Assembly | – | – | – | – | Composite |
| Engineering / platform design (EXTALON airframe platform, swept-wing architecture, dedicatedEngineering | – | 2.40 meters (wingspan) | 25 kilograms (MTOW) | – | Composite |
1 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Thermoforming line / forming line | – | – | – | – | Hagen (Germany) |
Additional services
Quality
Production is organized as a series-capable industrial process; the cycle time is determined by the forming line. Further information on certificates and testing equipment is not published on the website.
| Evidence | Hagen |
|---|---|
| ISO 9001 |
History
- 2026
Market launch of the new EXTALON airframe platform by Stahlkontor Drone Systems (publication 03.09.2026, update 07.10.2026).