proven processes


At Blackhawk Composites, we consider you our partner. When you come to us requesting solutions to boost your aircraft’s performance, strength, and payload, we partner with you every step of the way, from the first conversation through final FAA approval of your new part.

Our full-service capabilities allow us to perform all of the following, in-house:

Create full CAD for your part

Build the required tooling

Produce a rapid prototype

Refine designs

Fabricate your part in-house

Refine designs

Fabricate your part in-house

Perform finish work

Test the part

Assist with FAA, EASA, and other regulatory approvals


Producing Your Part

At the beginning of the process, Blackhawk Composites’ engineering team works with you on a successful design. Whether you’ve come with a problem you want solved, a napkin drawing, or a full set of designs, we’ll review your needs and prepare a proposal, complete with recommendations for the best way to achieve your goal on your budget and timeline. In many cases, it is not uncommon for us to go from a design idea to a complete solution in only a few weeks.

Once you approve your design and quote for production, a purchase order is created to begin work. Your team at Blackhawk Composites will manage all aspects of production, from design review, tooling, and prototype to fabricating, finishing, testing, and assisting with all required regulatory approvals.


Throughout your journey with Blackhawk Composites, you will have a dedicated project manager to support you and your project. Your project manager works with the Blackhawk team to ensure your project meets your quality expectations and is on schedule, all while providing you with daily updates on progress and estimated delivery. Your project manager will also oversee the production of your part, performing a number of tasks, including ensuring:

  • The cross functional team’s review at the RFQ stage assures capability, capacity, and understanding of your requirements
  • Develop prints and specs are produced to accompany your CAD
  • Pre-approved rework procedures for specified conformance issues are established and followed
  • Management of the NCR process
  • Management of the ECR process for part or process changes

Case Study

Composite Solutions for Improved Performance

When certifying an engine upgrade solution for the Cessna Caravan 208B, Blackhawk Performance Upgrades turned to Blackhawk Composites to engineer and manufacture a new composite cowling to accommodate the upgraded aircraft’s larger, more powerful engine and dual port exhaust. The improved cowling design significantly reduces installation losses and improves inlet efficiency.

In full production today, the cowling is part of a complete performance solution increasing Caravan capabilities and helping operators do more and earn more. This industry success story is a model for how innovative composite use can improve legacy products while meeting market needs.


  • 54 individually molded components and 21 assemblies, adhesive bonded and mechanically fastened
  • The carbon/epoxy composite materials passed 16 different tests, using five samples each, for a total of 80 test conditions


November 22nd 2010

FAA approval of BCI facility and PMA Quality System

January 18, 2011

FAA approval of first article components for the Blackhawk Modifications designed cowling for the modified Cessna Caravan 208B

April 13, 2011

FAA approval of first article of assemblies for the cowling

April 21, 2011

Cowling passed the static load testing exceeding structural design requirements

May 18, 2011

FAA approval of site equivalency test results for Toray T700S-12K material listed in the AGATE Database in accordance with FAA requirements 14 CFR Part 23 Section 23.613

June 22, 2011

Blackhawk Modifications receives Supplemental Type Certificate (STC) from the FAA and approval of the type design change authorizing modification of the Cessna Caravan 208B

June 23, 2011

Blackhawk Modification delegation for Blackhawk Composites to produce 21 assemblies for the cowling used on the modified Cessna Caravan 208B

June 29, 2011

Quality manual approval to new FAA requirements of CFR 21.308

July 16, 2011

Delivery of the first engine cowling for the modified Cessna Caravan 208B aircraft

June 22, 2011

First flight of the modified Cessna Caravan 208B with a Blackhawk Composites engine cowling

July 1, 2011

Parts Manufacturing Approval (PMA) granted by the FAA Vandalia Office allowing Blackhawk Composites to manufacture carbon/epoxy composite components for the modification to the Cessna Caravan 208B


Blackhawk Composites utilizes highly experienced composites engineers, technicians, and leadership with the latest techniques and technology to develop aerospace-grade composite parts and assemblies. Our full in-house services, centrally located for inexpensive shipment, offer considerable cost-savings and efficiency, while our open and transparent communication strengthens customer trust and confidence. Blackhawk Composites is your cost-effective, time-saving partner for performance enhancing solutions.