Flyber launches U.K. composites manufacturing site for advanced mobility applications

UAV composite propeller. Source | Flyby

Flyber (Kislingbury), a U.K.-based startup specializing in advanced design and manufacturing of propellers for unmanned aerial vehicles (UAVs) and advanced air mobility (AAM), has unveiled its new manufacturing site in Northampton. It is aimed at transforming structural component fabrication for mobility markets, including aerospace, electric vertical takeoff and landing (eVTOL) vehicles, UAVs and the wider AAM market with an initial focus on composite propellers — in Flyber’s view, the hardest to get right, to prove their value.

Flyber’s core innovation lies in its composite-first design platform, which uses proprietary algorithms and in-house developed simulation tools to generate optimized structural propeller components that fully leverage the performance characteristics of carbon fiber. The platform directly connects design intent with automated manufacturing, Flyber explains, reducing time-to-part and material waste.

Featured Content

Assembling the Multifunctional Fuselage Demonstrator: The final welds READ MORE

Automated Composites Knowledge Center READ MORE

Biomaterials make strides toward composites sustainability READ MORE

“Composites have long promised unmatched strength-to-weight ratios, but have historically come with trade-offs in design flexibility, production scalability and cost,” says Rowan Carstensen, co-founder and CEO of Flyber. “Our platform and process eliminates those trade-offs by combining software-driven design optimization with fully integrated manufacturing processes tailored to composite materials for propellers.”

Unlike traditional thermoset prepreg systems, Flyber’s solution requires no autoclave or extensive curing cycles, enabling on-demand, out-of-autoclave (OOA) part fabrication with enhanced recyclability and sustainable material use.

To validate its technology, Flyber has partnered with several AAM developers and universities and research centers within the U.K., France and Italy. In ongoing trials, Flyber-produced components have demonstrated cycle times of 15 minutes, improved aerodynamic performance of 30% (depending on the measure of performance), reduced weight by 5% and increased life cycles by 250%.

“Our customers are seeking production-ready composite propellers for their UAVs with bespoke performance according to their aircraft’s and end-user’s needs, along with high-volumes and reduced lead times,” says Carstensen. “Flyber bridges the gap the U.K. traditionally falls behind on in rapidly scaling manufacturing and services.”

Flyber’s modular, scalable manufacturing cells are currently being deployed, with plans to expand with customers in North America and Europe.