Aerospace & Defence Systems Hyderabad · 17.44°N 78.38°E

Purpose-driven Aerospace Solutions

We believe aerospace innovation should never be limited by technology or supply chains. That's why we build intelligent avionics, reliable aircraft power systems, and trusted material sourcing networks that help innovators move faster and build smarter.

Explore systems → View capabilities
Systems for
Military AircraftFighters · Bombers · ISR
ALT38,000ft
IAS312kt
HDG282°
MACH0.84
IST · HYDERABAD--:--:--
Mission

To help aerospace innovators move beyond limitations through intelligent systems, trusted sourcing, and engineering built for missions that matter.

Vision

A world where aerospace technology is smarter, safer, and built to move humanity forward.

What we hold to
  • QQuality
  • SSafety
  • RReliability
  • IInnovation
  • EExcellence
Domains served

Where our systems fly

From front-line fighters to drug-discovery models, the same airworthiness discipline runs through every programme we support, across the globe.

MIL

Military Aircraft

Fighters · Bombers · ISR

CIV

Civil Aviation

Airliners · Regional · GA

UAV

UAV Systems

Unmanned · Autonomous

ROT

Helicopters

Attack · Transport · SAR

MSL

Missiles & Launch

Guided · Precision Strike · Launch Vehicles

AI

Artificial Intelligence

ML · Neural Networks · Autonomy

BIO

AI Life Sciences

Drug Discovery · Diagnostics

Product portfolio · 5 divisions

Precision systems

Five divisions, one supply discipline. Every item ships with its standards trail, from cell to LRU to the shelter that houses it.

Power Systems DivisionBAT-01

NiCd & Li-Ion Aircraft Batteries

Main, emergency, and APU batteries. Sealed NiCd and Li-Ion packs certified to DO-160 and MIL-SPEC for commercial, military, and business aviation platforms, with integrated BMS and thermal protection.

ChemistriesNiCd · Li-Ion · VRLA · Ag-Zn
QualifiedDO-160G · IEC 60952
PlatformsLCA · P-8I · Navy
Open division →
Sealed cylindrical aircraft battery cells
Materials DivisionMAT-02

Aluminium, Steel & Titanium Stock

Certified aerospace-grade aluminium alloys (2024, 6061-T651, 7075), stainless steel (SS 321, 304L, 15-5PH), and titanium (Ti-6Al-4V) sheets, coils, plates, and bar stock, traceable to AMS and ASTM standards.

Grades live304L · 316L · AMS 4027
QualityBS EN 9120:2018
BuyersHBL · BEL
Open division →
Hot-rolled steel coil glowing in the mill
AI Systems DivisionAI-03

AI-Driven Aerospace Systems

Machine-learning flight management, predictive maintenance algorithms, autonomous mission decision engines, and AI-integrated health monitoring for next-generation civil and defence platforms.

Edge latency< 8 ms
Link uptime95%+
Bandwidth−60%
Open division →
AI processor projecting an aircraft wireframe
Avionics DivisionAVN-04

Flight Deck & Sensing Systems

Actuators, air data computers, INS/GPS navigation, AHRS, angle-of-attack sensors, static inverters, and integrated avionics suites, qualified to DO-178C, DO-254, and FAR Part 25 requirements.

SoftwareDO-178C
HardwareDO-254
Databus1553 · A429
Open division →
Glass cockpit flight deck at dusk
Ground Systems DivisionDLS-05

Military-Grade Data Link Shelters

Hardened, MIL-STD-qualified mobile shelters for secure UAV command and control. TEMPEST-grade EMI/RFI shielding, redundant power, and active thermal management for the data link, LRUs, and operators.

EnvironmentMIL-STD-810
EMIMIL-STD-461
Range200 km
Open division →
Trailer-mounted military shelter deployed in the field
Live contracts · Mission operations

Current running projects

Contract execution status across defence PSUs and the Indian Navy. Each programme is tracked from purchase order to certified delivery.

LiveMachworks AI Pvt. Ltd. · Programme board
5Programmes
4Active
1Delivered
  • Delivered 1
  • In progress 2
  • Early stage 1
  • Initiated 1
  1. M-01Completed

    Supply of AMS-spec SS304L sheets for NiCd battery, LCA Mk1A

    LCA Mk1ANiCdSS304L
    100%Delivered
  2. M-02Early stage

    Supply of AMS-spec SS316L & 6061-T6 aluminium sheets, BEL Pune

    SS316LAl 6061-T6BEL Pune
    10%Phase · PO
  3. M-03In progress

    Supply of sealed cylindrical cells, Type D 5000 mAh, HBL

    CylindricalType D5000 mAhHBL
    50%Phase · Production
  4. M-04In progress

    Sealed cylindrical cells, Type D 3000 mAh, HBL

    CylindricalType D3000 mAhHBL
    50%Phase · Production
  5. M-05Initiated

    Supply of LiFePO₄ battery, Indian Navy, Goa

    LiFePO₄Indian NavyGoa
    5%Phase · PO
Core competencies

What we deliver

Six disciplines powering the next generation of aerospace, run by one team that understands both the engineering and the airworthiness paperwork behind it.

Avionics

Avionics design & development

End-to-end design and development of flight instruments, navigation systems, and integrated avionics suites certified to DO-178C and DO-254.

Design & DevelopmentDO-178CDO-254
Intelligence

AI enhanced systems

Machine learning in flight management, predictive maintenance, autonomous navigation, and real-time mission decisions.

Machine Learning
Power

Aircraft power systems

Li-Ion and Ni-Cd batteries, static inverters, transformer rectifier units, and power distribution for commercial and military platforms.

Power & Energy
Materials

Aerospace raw materials

Global sourcing of certified aluminium alloys, titanium, composites, specialty polymers, and advanced structural materials.

Materials & Supply
Trade & Certification

Global trade & certification

End-to-end management of ITAR, EAR, customs compliance, and dual-use export controls across 40+ countries, unified with CEMILAC, Aerograde, and DGCA airworthiness support, STC development, and DO-178C/254 certification pathways.

ITAR · EAR · SCOMETCEMILACDGCASTC
By the numbers
40+countries reached by our trade desk
24hresponse on every qualified enquiry
Shelters

Data link shelters

Ruggedised, trailer-mounted mobile shelters towed by a prime mover, housing pilots, LRUs, and the data link. A low-rate command uplink pairs with a high-rate video and telemetry downlink, under thermal management and EMI shielding.

Ground SystemsMIL-STD-810TEMPEST
About us · Founded by IISc Bangalore alumni

Who we are

Born from the excellence of IISc Bangalore, our team brings together aerospace engineers, AI innovators, industry leaders from Dell and TCS, doctoral researchers, strategic thinkers, UPSC achievers, and experienced industrialists, united by one belief: the future of aerospace must be built smarter, faster, and with purpose.

We combine deep engineering, intelligent systems, and real-world execution to solve complex aerospace and global trade challenges with precision and trust.

Because in aerospace, technology alone is not enough. Vision, reliability, and the people behind it are what truly move the future forward.

“Where IISc rigour meets aerospace ambition. Precision is not a goal, it is our foundation.”
Human intelligence · Neural cluster 01

The minds behind the machine

A convergence of IISc research pedigree, global industry execution, and deep domain expertise.

Founding leadershipLayer 01
R
Founder & Chief Aerospace Architect

Mr. Rayan

ME (AE) · IISc Bangalore

The visionary behind Machworks: an IISc-trained aerospace engineer with mastery across the full aerospace design spectrum. His research-driven approach is the cornerstone of Machworks' capability in solving complex certification challenges, from structural airworthiness to DO-178C/254 compliance pathways.

Full-spectrum AE designCertification strategyDO-178C / DO-254Structural airworthiness
J
Co-Founder & Head of Global Trade

Mr. Jagan

ME (AE) · IISc Bangalore

An aerospace engineer turned global trade strategist, Jagan brings IISc technical depth with hands-on expertise in international supply chain management. He architects Machworks' global sourcing and cross-border trade operations, navigating ITAR, SCOMET, and multi-jurisdiction compliance.

Global supply chainITAR · SCOMETTrade complianceOEM liaison
Core executive teamLayer 02
RT
Executive Director

Dr. Rama Tulasi

PhD · Pharma · AI & Data Analytics

Leads strategic direction with an interdisciplinary lens spanning chemistry, AI, and data analytics, shaping the company's AI-enhanced research and data intelligence capabilities.

AI strategyData analyticsChemistry
AJ
Business Development Lead

Amruth J N

MS · United Kingdom

A UK Master's and a record of building businesses from the ground up. Amruth drives commercial growth: partnerships, client acquisition, and revenue expansion across global aerospace markets.

Business devEntrepreneurshipGlobal markets
R
Head of Human Resources

Ms. Rama

MA Psychology · BTech · Ex-TCS · Ex-Google

A former TCS and Google executive bringing corporate culture and people operations expertise, bridging technical talent and human intelligence into a high-performance, cohesive team.

Ex-GoogleEx-TCSTeam building
Strategic advisors · IISc & industryLayer 03
BM

Mr. B Mohan

ME (SSA) · IISc

Over half a decade at Mercedes-Benz, Germany, building AI-enhanced intelligent systems with automotive and aerospace-grade rigour.

AI systemsMercedes-Benz
AK

Mr. Akhilesh

ME (CITD) · IISc

Texas Instruments alumnus with deep expertise in system design and product engineering for embedded and AI system architecture.

Systems designTexas Instruments
RJ

Mr. Ramjee

ME (Civil) · IISc

Civil and structural engineering expert: raw materials evaluation, structural integrity assessment, and sourcing for high-performance aerospace use.

Raw materialsStructural eng.
RV

Mr. Ravi

MSc (USA) · BTech (IN)

Industry partner specialising in shelter construction systems and antenna/electronics for datalink communication systems.

DatalinkShelter systems
Get in touch

Request a quote

Delivering mission-critical aerospace components, power systems, and AI-driven solutions to defence primes, airlines, and MRO operators across 40+ countries. We respond to every qualified enquiry within 24 hours.

Sales enquiries
info@machworks.ai
Global headquartersSy. No 64, Building No. 9, 13th Floor
Mindspace, Madhapur, HITEC City
Hyderabad, India 500081
Direct lines
+91 94904 95607+91 91535 23456+91 90149 32720
Recognitions
Startup India · DPIITMCA RegisteredGST · Govt. of IndiaMSME · Udyam
Response windowWithin 24 hours · Mon to Sat
01 Contact details
02 Product details
03 Requirement
0 / 200 words
Your details go only to the Machworks sales desk.
Aircraft battery cell rendered in blue light
Power Systems Division · BAT-01

Aircraft batteries

Five proven chemistries power the world's aircraft: Nickel-Cadmium, Lithium-Ion, Lithium Iron Phosphate, Lead Acid, and Silver Zinc. Each is engineered for a different mission envelope, all certified to the highest aerospace standards.

CEMILAC ApprovedDGCA · FAA · EASAIEC 60952 · DO-311A
Bus status● Nominal
NiCd cell1.2V
Li-Ion cell4.2V
Range−40/ +70 °C
Active5missions
Live contracts · Mission operations

Current running projects

Real-time contract execution status for Machworks AI Pvt. Ltd.

LivePower systems · Programme board
5Programmes
4Active
1Delivered
  • Delivered 1
  • In progress 2
  • Early stage 1
  • Initiated 1
  1. M-01Completed

    Supply of AMS-spec SS304L sheets for NiCd battery, LCA Mk1A

    Platform · LCA Mk1AChemistry · NiCdMaterial · SS304L
    100%Delivered
  2. M-02Early stage

    Supply of AMS-spec SS316L & 6061-T6 aluminium sheets, BEL Pune

    SS316LAl 6061-T6BEL Pune
    10%Phase · PO
  3. M-03In progress

    Supply of sealed cylindrical cells, Type D 5000 mAh, HBL

    CylindricalType D5000 mAhHBL
    50%Phase · Production
  4. M-04In progress

    Sealed cylindrical cells, Type D 3000 mAh, HBL

    CylindricalType D3000 mAhHBL
    50%Phase · Production
  5. M-05Initiated

    Supply of LiFePO₄ battery, Indian Navy, Goa

    LiFePO₄Indian NavyGoa
    5%Phase · PO
Battery chemistries

Four proven chemistries that power aerospace

From a century-old aviation gold standard to high-density lithium and mission-specific silver-zinc, each chemistry is engineered for a precise operating envelope. Selecting the right one is the foundation of every successful power architecture.

Indian Navy Boeing P-8I in flight over the Indian Ocean
Reference platformBoeing P-8I Poseidon · Indian Navy
Two HAL Tejas light combat aircraft in formation
Reference platformHAL Tejas · Indigenous Light Combat Aircraft
Dassault Rafale M launching from an aircraft carrier
Reference platformDassault Rafale M · Carrier-borne multirole
INS Kalvari Scorpène-class submarine at sea
Reference platformINS Kalvari · Scorpène-class submarine
No. 01 · Nickel Cadmium · NiCd

The aviation gold standard

DO-160G · IEC 60623MIL-PRF-8565 · CEMILAC

A century of proven airworthiness. From Arctic cold-soaks to tropical heat cycles, NiCd cells deliver the same predictable response across every flight envelope. Linear capacity fade, never sudden death, gives mission planners a chemistry they can trust on day 1 and year 20 alike.

  • No sudden-death failure: linear, predictable capacity fade
  • Withstands unlimited overcharge, vibration, and mechanical shock
  • Proven on P-8I, C-17, Hawk, Dornier 228, and 1,000+ platform types
  • AMS-qualified materials; DO-160G qualified assemblies
No. 02 · Lithium-Ion · NMC

Maximum energy, minimum weight

DO-311A · IEC 62133MIL-PRF · UN 38.3

India's combat aircraft programmes, from Tejas to AMCA, are built around weight-critical energy. Li-Ion NMC delivers 3× the energy density of NiCd in the same footprint. An integrated BMS governs every cell for over-voltage, thermal runaway, short-circuit, and state of charge.

  • Full discharge in under 10 min: emergency power proven on F-35 class
  • Operates at −40 °C without heater, UAV and space-platform validated
  • BMS-managed over-voltage, thermal, and short-circuit protection
  • 3× energy-to-weight ratio versus NiCd
No. 03 · Lead Acid · VRLA · AGM

Proven economics, zero compromise

DO-293 · TSO-C173MIL-B-8565 · IEC 60952

The most cost-effective certified chemistry in aviation. Sealed VRLA with AGM separator delivers massive cold-cranking surge, maintenance-free operation, and an unmatched global service network for APU start, ground support, and trainer fleets.

  • Lowest cost per Wh of any certified aviation chemistry
  • Sealed AGM: no maintenance, no spill, any orientation
  • Cold-cranking surge of 500–1,200 A peak
  • Certified on 10,000+ active airframes worldwide
No. 04 · Silver Zinc · Ag-Zn

Peak power for peak missions

MIL-PRF-49471MIL-B-18728 · DEF-STAN

Silver Zinc delivers the highest aqueous specific energy of any chemistry, 40% greater than NiCd. Water-activated reserve variants keep a decade-long dry shelf life, and there is no thermal runaway pathway. Mission-proven from Apollo to BrahMos.

  • Highest aqueous specific energy: 40% above NiCd at cell level
  • Pulse power above 1 kW/kg instantaneous discharge
  • Water-activated reserve variant with 10+ year dry shelf life
  • Apollo LM, Mk-48 torpedo, BrahMos propulsion
Performance comparison

Chemistry vs mission profile

Selecting the right chemistry depends on your platform's voltage, weight, temperature, cycle life, and certification needs. The matrix benchmarks each against the parameters that matter on the flight line.

ParameterNiCdLi-IonVRLASilver Zinc
Energy densityLowVery highLowHighest
Cell voltage1.2 V3.6–4.2 V2.0 V1.55 V
Cycle lifeVery high~1,000~500~200
Low-temp performanceExcellentVery goodFairVery good
Thermal safetyExcellentModerateVery goodExcellent
Primary applicationAPU · Emergency · Commercial ACAvionics · UAV · Combat ACGA · Trainer · GSE · APUMissiles · Torpedoes · Space
Standards & certifications

Qualified against every body that matters

Every cell, every assembly, every batch. From RTCA and FAA in commercial aviation to MIL-STD and DEF-STAN for defence, with full alignment to Indian certification authorities.

RTCA

US aviation standards

  • DO-311A
  • DO-293
  • DO-160G
  • FAA TSO-C173 / C179
IEC

International electrotechnical

  • IEC 60952
  • IEC 60623
  • IEC 62133
  • IEC 62660
MIL · DEF

Defence specifications

  • MIL-PRF-8565 / 81757
  • MIL-PRF-32052 / 49471
  • MIL-STD-810H · 461F
  • DEF-STAN · BS EN 2570
Indian · Quality

National & audit bodies

  • CEMILAC · DGCA
  • EASA · IS 10918
  • SAE AS6171 · AS9100D
  • DEKRA certified
Sealed cylindrical NiCd and Li-Ion cells, aircraft grade
Cell-level capability · 18650 · 26650

Aerospace-grade sealed cells

Beyond complete battery assemblies, Machworks delivers the building block itself: DO-160 qualified sealed cylindrical cells. The same cell platform powers our NiCd reserves and our high-energy Li-Ion packs, used as OEM building blocks by Indian Navy, HAL, and BEL programmes.

DO-160G · UN 38.3IEC 62133 · MIL-PRF-32383
Formats18650 / 26650 / Sub-C
Capacity1.5 – 5.0 Ah
NiCdSub-C · D · F
QualificationDO-160G
  • Hermetically sealed steel casing with integrated vent, zero electrolyte leakage
  • Operates −40 to +70 °C without external thermal management
  • Modular building block from single-cell reserves to multi-kWh stacks
  • Supplied as OEM components to Indian Navy submarines, HAL Tejas, and BEL avionics

Request a battery quote

Share your platform, voltage requirement, operating environment, and certification need. Our power systems team responds within 24 hours, Mon to Sat.

Request quote →
Next division · MAT-02Aero-grade materials
Aircraft fuselage frames and stringers under assembly
Materials Division · MAT-02

Aerospace & defence materials partner

Certified aerospace stainless steel and aluminium, from billet to finished sheet and coil. Three active programmes currently feeding HBL Power Systems and Bharat Electronics with AMS-traced 304L, 316L, and AMS 4027 stock.

AMS CertifiedBS EN 9120:2018Full mill traceability
Mill test report● Traceable
SS 304L UTS515MPa
Al 6061-T6 UTS310MPa
Grades live3
Specs12+
Aerograde material & systems capability
Stainless steel304L · 316L · AMS
Aluminium6061-T6 · Plate
TitaniumGrade 5 · Ti-6Al-4V
CopperHigh conductivity
SheltersUAV · Data link
Live material contracts

Current running projects

Real-time material supply status for HBL Power Systems and Bharat Electronics.

LiveMaterials · Programme board
3Programmes
2Active
1Delivered
  • Delivered 1
  • In progress 1
  • Early stage 1
  1. M-01 · HBLCompleted

    Supply of AMS-spec stainless steel 304L sheets for NiCd battery case manufacture

    SS 304L · AMS 5511SheetAnnealed
    100%Delivered
  2. M-02 · BELIn progress

    Supply of AMS-spec stainless steel 316L sheets for defence electronics enclosures

    SS 316L · AMS 5524SheetSolution annealed
    35%Phase · Sourcing
  3. M-03 · BELEarly stage

    Supply of AMS 4027 aluminium alloy 6061-T6 plate for avionics chassis

    Al 6061-T6 · AMS 4027PlateT6
    15%Phase · PO
Production process

Billet to certified sheet in five controlled stages

Every sheet, plate, and coil we supply traces its lineage from primary smelting through controlled rolling, heat treatment, and AMS-compliant inspection, with Mill Test Report documentation at every stage.

1

Primary smelting & alloying

Raw ore or scrap is melted in an electric arc furnace. Alloying elements are added to precise weight percentages per AMS chemistry limits.

EAF · VIM · VAR
2

Casting to billet / slab

Molten metal is continuously cast into billets, slabs, or ingots. A homogenisation anneal dissolves segregated elements uniformly.

DC cast · Continuous
3

Hot rolling to plate / strip

Slabs are heated above recrystallisation temperature and passed through reversing rolls, from 600 mm down to 6–80 mm plate.

Rolling mill
4

Cold rolling, quench & temper

Cold rolling refines gauge and surface. Solution heat treatment, rapid quench, and artificial ageing develop final properties.

T3 · T6 · T651
5

AMS inspection & certification

Chemistry (OES), tensile and yield, hardness, flatness, and finish are all tested. MTR issued with full heat and lot traceability.

AMS · MTR
Featured grades

Three grades in active production for defence PSUs

SS 304L and SS 316L stainless sheet, plus AMS 4027 aluminium plate: the three certified grades Machworks AI is currently supplying to HBL Power Systems and Bharat Electronics.

Stainless steel 304L sheets
Stainless · Austenitic · For HBL

SS 304L

AMS 5511 · UNS S30403

The workhorse low-carbon austenitic grade. Carbon limited to 0.030% suppresses chromium-carbide precipitation at weld zones; the standard chemistry for NiCd battery cases and welded aerospace enclosures.

UTS515 MPa
0.2% PS205 MPa
Thickness0.5–6 mm
Finish2B · BA
Current contractNiCd battery case sheet stock for HBL Power Systems
Stainless steel 316L coil in the rolling mill
Stainless · Mo-bearing · For BEL

SS 316L

AMS 5524 · UNS S31603

Adds 2.0–3.0% molybdenum to the 304 chemistry, sharply improving resistance to chloride pitting and crevice corrosion. The standard where defence electronics meet marine and salt-air environments.

UTS485 MPa
0.2% PS170 MPa
Mo content2.0–3.0%
Carbon≤ 0.030%
Current contractDefence electronics enclosure stock for BEL avionics & radar programmes
Aluminium 6061 sheets
Aluminium · Al-Mg-Si · For BEL

AMS 4027

Al 6061-T6 plate

The most versatile structural aerospace aluminium in service. Solution-heat-treated and artificially aged, with excellent weldability, corrosion resistance, and machinability for milled avionics chassis and brackets.

UTS310 MPa
0.2% PS276 MPa
Thickness6–150 mm
Density2.70 g/cc
Current contractAvionics chassis plate for BEL airborne & ground defence electronics
Supply forms

Sheet, plate & coil, cut to your spec

Slit-edge coil, mill-edge sheet, or hot-rolled plate. Cut to length, sheared, or supplied master-size for in-house processing.

Stainless steel sheet stack
Form 01

Sheet

Mill-rolled sheet, supplied 2B cold-rolled or BA bright-annealed. Standard for 304L and 316L.

0.5–6 mm1500 × 30002B · BA
Aluminium coil
Form 02

Coil & strip

Continuously rolled coil and slit strip for press-shop blanking, wound on AISI standard cores.

0.3–3 mmSlit-edgeØ 508 ID
Aluminium plate stack
Form 03

Plate

Heavy-section hot-rolled plate, machineable to chassis and structural billet. Standard for AMS 4027 6061-T6.

6–150 mmSaw-cutT6 temper
Inventory · Ready to ship

Available stock

On-hand AMS-certified stainless steel and aluminium across sheet, plate, and bar. All stock ships with full Mill Test Reports and heat traceability.

GradeAMS specFormAvailable sizesPrevious buyerStatus
SS 304L / 304AMS 5511 / 13Sheet
0.8 mm1 mm1.2 mm1.5 mm2 mm3 mm
HBL Power SystemsIn stock
Al 6061-T6AMS 4207Sheet / Plate
12.7 mm80 mm
Bharat ElectronicsIn stock
SS 316LAMS 5507Sheet
1.2 mm1.5 mm5 mm20.5 mm
Bharat ElectronicsIn stock
SS 316LAMS 5653Rod / Bar
Ø 20 mm
HBL Power SystemsIn stock
Quality standards & specifications · 3 grades · 12+ specs
AMS 5511 SS 304LAMS 5524 SS 316LAMS 4027 Al 6061-T6ASTM A240ASTM B209QQ-A-250/12BS EN 10088-2UNS S30403UNS S31603BS EN 9120:2018ISO 9001:2015NADCAPFull MTR suppliedHeat traceable
Shelter systems

Tactical shelters for UAV & data link stations

Lightweight, EMI-shielded transportable shelters for UAV ground-control stations, data-link terminals, and communications electronics. Foam-and-beam sandwich panels give high strength-to-weight, all-weather sealing, and field-proven RFI protection.

Shelter structural FEA stress analysis and chassis frame model
FEA · Structural validation

Finite-element validated shelter structures

Every shelter body and chassis frame is digitally validated through finite element analysis. Deformation, roof-load, and floor-payload stress fields are simulated before fabrication.

FEAStress & deflection
3DStructural frame CAD
RFI60 dB verified
BuildMIL-spec compliant
ISO 668 · 1496/1 · 1161 · 3874

Standard ISO 20 ft shelter

Deployable as command and communications centres, UAV posts, EW maintenance facilities, or data-link hubs. All-aluminium, all-welded, or fully customised construction.

Exterior238.5 × 96 × 96 in
Roof load40 lbs/ft² snow
Service life15 / 20 yr store
Operating−65 °F to +125 °F
MIL-S-55286E

S-280C/G shelter

Insulated all-weather shelter for transportable electronics. Polyurethane core, aluminium skins, and high-strength alloy extrusions in barrel-hoop construction. Transport by truck, helicopter, C-130, rail, and ship.

RFI shield60 dB · 150 kHz–10 GHz
Roof load75 lbs/ft²
Floor load2,500 lbs / 3 ft²
SpecMIL-S-55286E
Trailer-mounted military shelter deployed in the fieldLIVE · In theatre
Field deployed · Mobile

Trailer-mounted shelter

Rapidly relocatable UAV ground-control station or data-link node with integrated levelling jacks, single-axle chassis, and weather-sealed body.

Road-towableLevelling jacksReady on arrival
MIL-S-55286EASTM E1976ASTM E1977ASTM E1978ISO 668ISO 1496/1ISO 1161ISO 3874MIL-STD-285 RFI60 dB attenuationEMI/EMP shieldedAll-weather sealed

Request a materials quote

Share your AMS specification, grade, temper, thickness, width, length, and quantity. Our materials team responds within 24 hours with pricing, availability, and a sample Mill Test Report.

Request quote →
Next division · AI-03AI enhanced systems
AI processor projecting an aircraft wireframe
AI Systems Division · AI-03

AI enhanced aerospace systems

Machine learning and edge AI transforming UAV datalink performance: real-time video enhancement, predictive telemetry, intelligent spectrum management, and autonomous anomaly detection for next-generation unmanned platforms.

Edge AI inferenceReal-time processingMIL-STD compliant
Edge node · Jetson Orin NX● Inference
Link uptime95%+
Video clarity4×
Edge latency<8ms
Bandwidth−60%
System architecture

UAV datalink system: how it works

A UAV datalink carries two critical payloads at once: downlink video (HD/IR camera feeds) and bidirectional telemetry (GPS, attitude, sensor health, uplink commands). Without AI, both run on fixed protocols with no adaptation to the RF environment or mission context.

UAV datalink · full architecture · live
RF linkAI pathCommands / OTA
UAV PLATFORM HD / IR camera Telemetry · IMU · GPS EDGE AIOrin NX · <8 ms RF DATALINK AES-256 · LDPC FECCNN spectrum sensingFHSS adaptive hop GROUND STATION Operator display Mission computer Alerts · RTH<100 ms response enhanced video 4× SR video fused telemetry commands CLOUD TRAININGPyTorch → TensorRT → OTA mission datamodel updates
RF signal

One link, two payloads

HD/IR video downlink and bidirectional telemetry share a single RF datalink, so bandwidth allocation is mission-critical.

Edge AI inference

Under 8 ms

An on-platform AI engine (Jetson Orin NX) processes every signal in real time: super-resolution, spectrum sensing, anomaly detection.

Cloud learning

Continuous OTA

Mission data feeds a cloud training loop. Models improve continuously and push OTA updates to the fleet without ground intervention.

Secure & encrypted

AES-256 · LDPC

AES-256 encryption and LDPC forward error correction protect all AI-enhanced channels end to end across every link segment.

AI improvements

How AI transforms each datalink layer

Six AI subsystems each target a specific weakness in the conventional UAV datalink stack, from the RF physical layer up through the display layer.

Video

AI video super-resolution & enhancement

Conventional datalinks transmit compressed 720p or 1080p video. An onboard SRCNN / ESRGAN network reconstructs missing high-frequency detail, delivering 4K perceptual quality from a 1080p transmission: sharper target identification and terrain mapping with no extra RF bandwidth.

SRCNN · ESRGAN4× upscale<8 msJetson edge
Spectrum

Intelligent spectrum sensing & frequency hopping

A CNN spectrum-sensing model continuously maps occupied channels, jamming, and multipath, then commands the modem to hop to the clearest channel within milliseconds. Link uptime improves from about 75% to above 95% in typical contested airspace.

CNN RF classifierAnti-jammingFHSS adaptive95%+ uptime
Telemetry

Predictive telemetry & gap-fill reconstruction

When terrain masking or interference drops packets, an LSTM trained on UAV flight dynamics predicts the next 2–5 seconds of position, attitude, and velocity, filling the operator display seamlessly until the link recovers.

LSTM RNNKalman fusion2–5 s predictionMAVLink native
Health

Real-time anomaly detection & health prognosis

An autoencoder learns the normal distribution of every telemetry stream: motor current, vibration, battery curves, GPS accuracy, link quality. Deviations raise graduated alerts, and prognostic health management predicts failures minutes ahead to enable safe return-to-home.

AutoencoderPHM prognosisAll sensor streamsRTH automation
Codec

AI-driven video compression & bandwidth optimisation

A DNN perceptual codec gives high bitrate to regions of interest (targets, moving objects, landing zones) and compresses static background hard. Bandwidth drops by up to 60% while quality rises where it matters, extending range on the same RF hardware.

DNN perceptual codecROI encoding60% BW reductionH.265 compatible
Vision

Real-time object detection & target tracking

YOLOv8 / SSD runs at the edge before transmission, annotating vehicles, personnel, vessels, and runway markings with GPS-locked coordinates. Only a few KB/s of annotation travels alongside the video, cutting operator load and enabling target hand-off.

YOLOv8 / SSD30+ fpsGPS annotationMulti-class
Performance delta

Without AI vs with AI enhanced

Fixed protocol, no adaptation

Conventional datalink

  • ✗720p / 1080p compressed video, poor detail in target areas
  • ✗Fixed frequency channel, susceptible to jamming
  • ✗Telemetry gaps during dropout; operator loses awareness
  • ✗No health prognosis; failures occur without warning
  • ✗Uniform H.264 compression, high bandwidth on static scenes
  • ✗No object detection; manual target identification
  • ✗Link uptime ~70–75% in contested environments
  • ✗Full 10–20 Mbps consumed regardless of content
  • ✗Reaction to anomaly: minutes, if detected at all
Adaptive, intelligent, autonomous

Machworks enhanced datalink

  • ✓4K perceptual quality via ESRGAN from the same link
  • ✓CNN spectrum sensing, autonomous hop in under 10 ms
  • ✓LSTM gap-fill: zero-dropout display during RF interruption
  • ✓Autoencoder PHM predicts failure 3–8 minutes ahead
  • ✓DNN perceptual codec saves 60% bandwidth
  • ✓YOLOv8 overlay classifies targets at 30 fps
  • ✓Link uptime above 95% in EW-contested environments
  • ✓4–8 Mbps effective, enabling extended range or dual payload
  • ✓Reaction to anomaly under 100 ms with suggested response
4×Effective video resolution gain (ESRGAN)
95%+Link uptime in contested RF, up from ~72%
60%Bandwidth reduction (DNN perceptual codec)
<8msEdge AI inference latency on Jetson Orin NX
Technology stack

AI models & hardware stack

Production status for each function, with the hardware it runs on and measured performance.

AI functionModel / algorithmHardwareLatencyPerformanceStatus
Video super-resolutionESRGAN / SRCNNJetson Orin NX 16GB<8 ms4× upscale, PSNR +6 dBProduction
Spectrum sensingCNN radio classifierXilinx RFSoC FPGA<1 ms98.5% jamming detectionProduction
Telemetry predictionLSTM + Kalman filterJetson Orin / Cortex-A78<5 ms2–5 s lookahead, <0.5 m errorProduction
Anomaly detectionVariational autoencoderEdge AI accelerator<15 ms99.1% detection, <0.3% FPRValidation
AI video compressionDNN perceptual codecJetson AGX Orin<12 ms60% BW saving, +3 dB SSIMProduction
Object detectionYOLOv8 / SSD MobileNetJetson Orin / TPU<10 ms30 fps, mAP 0.87, 40+ classesProduction
Cloud training pipelinePyTorch / ONNX / TensorRTGPU cluster + OTA deployOfflineContinuous improvement loopOperational

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Next division · AVN-04Avionics systems
Night cockpit with glass flight displays
Avionics Division · AVN-04

Avionics systems & AI

Certified flight instruments, navigation computers, sensor systems, and AI-augmented avionics for fixed-wing, rotary, and unmanned platforms, qualified to DO-178C, DO-254, and MIL-SPEC.

DO-178C certifiedAI-augmentedMIL-STD-1553ARINC 429
Product catalogue · 8 LRU families

Avionics systems & subsystems

Machworks AI supplies, integrates, and qualifies a broad range of avionics Line Replaceable Units for OEM, MRO, and defence procurement channels worldwide.

Flight management system route display
Flight management

Flight Management System (FMS)

4D trajectory planning, LNAV/VNAV, performance management, fuel prediction, and ACARS/ATC datalink integration. Compatible with Honeywell FMZ-2000, Universal Avionics UNS-1Ew, and custom FMS architectures.

LNAV / VNAVRNP AR 0.1DO-178C DAL-BARINC 429/664
Glass cockpit with navigation displays
Navigation systems

INS / GPS navigation computer

Ring Laser Gyro and MEMS inertial systems, multi-constellation GNSS receivers, and navigation computers providing position, velocity, and attitude with GPS/INS fusion, RAIM integrity monitoring, and anti-spoofing.

RLGMulti-GNSSRAIM / FDEDO-229E
Head-up display artificial horizon
Attitude sensing

AHRS: attitude & heading reference

MEMS and solid-state AHRS providing high-rate roll, pitch, heading, and angular rate, with magnetometer integration, GPS-aided drift correction, and AI-based bias compensation.

MEMS / solid-state100 Hz outputMIL-STD-1553ARINC 429
Airliner nose and pitot probes on a snowy apron
Air data

Air Data Computer (ADC)

Computes IAS, TAS, Mach, altitude, vertical speed, and angle of attack from pitot-static inputs, with AI icing detection, sensor health monitoring, and plausibility cross-checks.

IAS / TAS / MachAI icing detectDO-160GRS-422
Radio altimeter antennas under an aircraft fuselage
Proximity sensing

Radio altimeter & TAWS

FMCW radar altimeters for precise AGL height from 0–2500 ft for CAT II/III autoland and terrain awareness. AI terrain profiling with digital elevation models looks beyond the beam footprint.

FMCW 4.3 GHz0–2500 ft AGLCAT III autolandTSO-C87a
TCAS traffic display with intruder targets
Collision avoidance

TCAS II & DAA system

TCAS II with AI-enhanced Detect and Avoid for manned and unmanned platforms: transponder interrogation, intruder tracking, resolution advisories, and trajectory prediction for BVLOS per ASTM F3442.

TCAS II v7.1DAA BVLOSDO-185BASTM F3442
Autopilot mode control panel
Flight control

Autopilot & AFCS

Automatic flight control with PID and AI-augmented reinforcement learning control laws for turbulence compensation, CAT III autoland, and UAV autonomy. Certifiable architecture under DO-178C DAL-A.

PID + RL hybridTurbulence adaptDO-178C DAL-AUAV autonomy
EMI shielding gaskets and honeycomb vent panels
EMC / protection

HIRF, EMC & EW hardening

HIRF protection, EMC design, and EW hardening for avionics LRUs: shielded enclosures, filtered connectors, ground-plane engineering, and AI detection of jamming and spoofing. Tested to DO-160G and MIL-STD-461G.

DO-160G Cat RMIL-STD-461G80 dB shieldingAI threat detect
AI advancements

How AI is transforming avionics

Academic research, industry programmes, and Machworks AI's own development are converging on six AI applications in avionics, with performance evidence from peer-reviewed sources.

Control

Neural network flight control

Reinforcement learning agents augment classical PID control laws with superior turbulence rejection, adaptive gain scheduling, and reconfiguration after actuator failure. NASA's F-15 ACTIVE and DARPA's X-62A VISTA validated AI flight control at full scale.

40%reduction in structural load under severe turbulence vs classical PID, in NASA RL autopilot trials
References
  1. NASA TM-2020-001467, Reinforcement Learning for Flight Control (NASA NTRS, 2020)
  2. Jiang et al., "Deep RL for Aircraft Autopilot", AIAA SciTech 2021
  3. DARPA ACE Programme, X-62A VISTA AI Dogfight (DARPA, 2023)
Health

AI fault diagnosis & PHM

CNNs and LSTMs analyse LRU sensor streams to detect incipient faults 3–15 minutes before failure, turning reactive maintenance into prognostic health management. Honeywell and Boeing use neural networks for fleet-wide avionics fault prediction.

99.1%fault detection accuracy with <0.3% false positives, LSTM-based avionics PHM (IEEE AES 2022)
References
  1. Zhao et al., "LSTM-based Avionics PHM", IEEE Trans. Aerospace & Elec. Sys. 2022
  2. Liu et al., "Deep Learning for Aircraft System Fault Detection", Adv. Eng. Informatics 2021
  3. Honeywell Aerospace Analytics, Predictive Maintenance Platform
Navigation

AI-enhanced navigation & GNSS integrity

AI sensor fusion combines INS, GPS, visual odometry, barometric altimetry, and LIDAR to hold navigation integrity through GPS denial, jamming, or spoofing. Deep-learning RAIM outperforms classical RAIM in multi-threat environments.

10×navigation availability under GPS denial using AI sensor fusion vs GNSS-only (SESAR 2025)
References
  1. Li et al., "Deep Learning RAIM for Multi-Constellation GNSS", ION GNSS+ 2021
  2. SESAR AI4SAFE Project, AI for Safety-Critical Avionics Navigation
  3. Brossard et al., "AI-IMU Dead-Reckoning", IEEE Trans. AES 2020
Vision

Computer vision & enhanced SVS

AI synthetic and enhanced vision systems use object detection and semantic segmentation to identify runways, taxiways, obstacles, and traffic in low visibility. NASA's Safe2Ditch uses computer vision for autonomous emergency landing site selection.

CAT IIIequivalent visibility operations enabled by AI-EVS in zero-visibility conditions (EASA Phase III)
References
  1. NASA Safe2Ditch, AI-based Emergency Landing Site Selection (NTRS, 2021)
  2. Park et al., "Deep Learning Runway Detection for EVS", AIAA Aviation 2022
  3. EASA EVS Research Programme, AI Enhanced Vision Findings
Security

AI cybersecurity & anomaly detection

AI intrusion detection using one-class SVMs and autoencoders monitors MIL-STD-1553 and ARINC 664 bus traffic, flagging anomalous timing, unexpected data words, or spoofed addresses. DO-326A and ED-202A require AI-aware threat modelling for Part 25.

<1 msintrusion detection response on a MIL-STD-1553 bus using autoencoders (AFIT 2023)
References
  1. Haman et al., "ML Intrusion Detection on MIL-STD-1553", IEEE Access 2023
  2. FAA DO-326A, Airworthiness Security Process Specification
  3. Sampigethaya & Poovendran, "Avionics Cyber Threat Landscape", IEEE AES 2021
Certification

AI for avionics certification

EASA's AI trustworthiness concept paper and the FAA AI/ML roadmap define certification pathways under DO-178C and the forthcoming DO-178D. Formal verification and explainability frameworks are becoming certification evidence. Machworks AI follows EASA's DEEL-DPAE framework.

DAL-Bfirst AI/ML avionics components reaching Design Assurance Level B under EASA pathways (2024)
References
  1. EASA Concept Paper, AI/ML Trustworthiness in Aviation (Issue 2, 2023)
  2. FAA AI/ML Roadmap for Aviation (FAA, 2024)
  3. Kurd et al., "Certifying Neural Networks in Safety-Critical Systems", AIAA SciTech 2022
Performance delta

Conventional vs AI-augmented avionics

Avionics functionWithout AIWith AI (Machworks)
Flight control✗ Fixed PID, manual gain tuning per flight envelope✓ RL-adaptive gain, self-tunes across all conditions
Fault diagnosis✗ CAS warnings after failure, reactive maintenance✓ LSTM PHM, 3–15 min advance warning
Navigation (GPS denied)✗ INS dead-reckoning, error grows unbounded✓ AI sensor fusion, <10 m error for 30+ min
Collision avoidance✗ TCAS II reactive RA, 25–35 s before CPA✓ AI DAA, 90 s look-ahead with trajectory prediction
Weather / obstacle detect✗ Wx radar only, no object classification✓ CV + Wx fusion: runway, obstacle, bird classification
Cybersecurity✗ No real-time bus monitoring, post-incident forensics✓ Autoencoder IDS, <1 ms anomaly detect on 1553 bus
FMS route planning✗ Static route, pilot updates for wx/TFR✓ AI 4D optimisation, real-time reroute, 6–12% fuel save

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Our avionics engineers will discuss your platform requirements, certification pathway, and AI integration options, with a technical response within 24 hours.

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Next division · DLS-05Data link shelters
Ground Systems Division · DLS-05

Data link shelters & GCS

Hardened, MIL-STD-qualified mobile shelters for secure UAV command and control, with TEMPEST-grade EMI/RFI shielding, redundant power, and active thermal management housing the data link, LRUs, and operators.

MIL-STD-810 qualifiedTEMPEST shieldedRapid deployIP65
Data link · secure● Linked
UplinkC2enc
DownlinkHDvideo
Range200km
Latency<50ms
Shelter portfolio

Mobile command & data link shelters

Machworks AI designs and integrates ruggedised shelters for ground control stations, tactical data links, and mission command, delivered trailer-mounted, vehicle-mounted, or as fixed installations.

Trailer-mounted ground control station shelter
Command & control

UAV ground control station shelter

Fully integrated GCS shelter housing operator consoles, mission computers, and communications racks. Low-rate encrypted command uplink paired with high-rate video and telemetry downlink for resilient operation in contested environments.

Dual operatorAES-256 C2 linkRedundant power
RF gaskets and honeycomb waveguide vents for shielded enclosures
EMI / RFI protection

TEMPEST-grade shielded enclosures

Engineered to MIL-STD-461 emission and susceptibility limits with TEMPEST-grade attenuation, filtered power entry, waveguide vents, and RF-gasketed doors protecting data link and cryptographic equipment.

MIL-STD-461>80 dB attenuationFiltered power
FEA stress model of a shelter body and frame
Environmental control

Power & thermal management

Redundant power with UPS backup and generator integration, plus an active ECU keeping equipment and operators comfortable from −40 °C to +55 °C, qualified to MIL-STD-810 shock, vibration, and ingress.

N+1 power−40 °C to +55 °CMIL-STD-810
Shelter structures & specifications →

Deploy a hardened ground segment

Talk to our ground-systems team about shelter configuration, shielding levels, data link integration, and delivery timelines, with a technical response within 24 hours.

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Back to the start · BAT-01Aircraft batteries