Composite Solutions


Performance Enhancement

Blackhawk Composites is a comprehensive composite design and manufacturing facility focused on boosting aircraft performance and capabilities. Our services include design support, prototype creation, building, and certifying composite components. Composites are lighter, stronger, and more durable than standard aerospace and high performance industry materials, offering opportunities for increased performance, strength, and payload while reducing maintenance costs. At Blackhawk Composites, we deliver diverse solutions tailored to your needs while our fully in-house services and cost-saving techniques give you the competitive advantage. If it’s increased performance you seek, we can help.


As commercial and military aircraft operators demand product upgrades, OEM and aftermarket providers are responding with innovative composite solutions to enhance legacy aircraft performance and efficiency. Blackhawk Composites is uniquely qualified to engineer, prototype, and produce complete composite solutions to meet exacting aerospace industry standards and requirements. We are one of just a few companies approved to utilize Toray carbon epoxy composite material, the same material used on commercial jetliners and favored by the FAA.


Our Morgantown, Kentucky, composite engineering and manufacturing facility houses the state-of-the-art equipment required to manufacture, test, and certify your aerospace-quality composite solutions to rigorous specifications. Centrally located in a low-cost labor market, we’re dedicated to offering our customers a cost-effective advantage.

Boasting a 98% first pass yield and 100% on-time delivery, Blackhawk Composites today manufactures components for more than a dozen programs and has either led or partnered with customers to manufacture and certify more than 50 projects.


Aerospace-grade quality composite manufacturing begins with advanced tools designed for pinpoint accuracy through every phase to ensure exceptional end results. Blackhawk Composites invests in the latest technology, allowing us to manufacture your composite products in-house, giving you the cost-competitive advantage.

  • 5-foot x 20-foot autoclave with 85psi/400˚F maximum operating capacity
  • Laser placement system for laser ply placement
  • Clear coat specific paint booth for processing exposed carbon
  • Autometrics CNC Plycutter
  • Weld equipment
  • Rivet equipment for assembly
  • 38,510-square-foot manufacturing facility
  • Large walk-in 0˚ F material storage
  • Temperature and humidity controlled clean manufacturing area
  • 10-foot platinum FaroArm with laser scanner for dimension verification
  • Curing equipment with 500˚ F capability
  • Grinding booths
  • Paint booths


Blackhawk Composites offers a diverse set of complete in-house services, giving you the cost-effective advantage. Our lean, time-saving processes mean you could have your solution in as little as a couple of weeks, while our cost-saving methods help ensure your project stays on budget. Our capabilities also include DERs for certification approvals, which means our customers experience shortened lead times and reduced costs while utilizing the best products in the industry.


With an exclusive focus on composite materials for aerospace, Blackhawk Composites is uniquely qualified to engineer, prototype, and produce complete composite solutions to meet rigorous aerospace industry standards and requirements.

Blackhawk Aerospace Composites Certifications:

  • FAA/PMA Approvals
  • FAA Composite Manufacturing Facility
  • NIAR Qualified Processes
  • AS9100D Certified (as Blackhawk Composites, Inc.)
  • ITAR Registered Compliant


Contact us today to discuss how our full-service composites capabilities can help you gain a competitive advantage.