Composite technologies in the HAPS ApusNeo project
The article highlights the composite technologies used in the ApusNeo 18 project, an 18-meter-wingspan platform developed under the HAPS (High Altitude Platform Station) program of Mira Aerospace. Mira Aerospace is a joint venture between Bayanat, part of Abu Dhabi-based G42, a global leader in artificial intelligence (AI), and UAVOS Inc., a developer and manufacturer of advanced unmanned systems.
The focus is on material selection, advanced manufacturing methods, and optimized production processes that deliver exceptional strength at minimal weight, high reliability, and cost-efficient production.
Modern aerospace projects require advanced composite solutions. HAPS ApusNeo with a wingspan of 18 meters demonstrates how the integration of materials science, manufacturing technologies, and rigorous process control enables high performance. The selection of manufacturing technologies and efficient production process management plays a key role in the success of this project.
The focus is on material selection, advanced manufacturing methods, and optimized production processes that deliver exceptional strength at minimal weight, high reliability, and cost-efficient production.
Modern aerospace projects require advanced composite solutions. HAPS ApusNeo with a wingspan of 18 meters demonstrates how the integration of materials science, manufacturing technologies, and rigorous process control enables high performance. The selection of manufacturing technologies and efficient production process management plays a key role in the success of this project.
Key Project Objectives
- Identify and implement composite technologies that meet strength, stiffness, and weight requirements.
- Ensure product reproducibility and quality at every stage of the production cycle.
- Deploy advanced technologies and equipment to reduce development cycles and production costs.
- Ensure the safety and reliability of finished parts under operational conditions.
Materials and Composite Solutions
ApusNeo utilizes state-of-the-art aerospace-focused technologies and materials.
Key components include:
Key components include:
- High-modulus CFM (Carbon Fiber Material), providing the necessary strength with minimal weight.
- Low-density PMI cores for sandwich structures with high mechanical properties and thermal stability.
- Prepregated composite materials with low binder content, varying in density and stiffness, developed specifically for the project's requirements by our supplier partners.
Production and Molding Technologies
One of the most important challenges is producing high-quality parts using a modern autoclave molding process.
The following parameters are used for ApusNeo:
Proper tooling (moulds) plays a crucial role. It is essential that the moulds withstand the specified temperatures and pressures and have a coefficient of linear expansion close to that of the component. Our tooling is manufactured from carbon prepreg.
The following parameters are used for ApusNeo:
- Molding temperature: 120–180°C
- Pressure: 5–8 bar
Proper tooling (moulds) plays a crucial role. It is essential that the moulds withstand the specified temperatures and pressures and have a coefficient of linear expansion close to that of the component. Our tooling is manufactured from carbon prepreg.
Aliaksei Stratsilatau, CEO of UAVOS
January, 2026