From Design To Flight
From envelope fabrication to motor assembly and 3D-printed components, every part of our airship is designed, manufactured, and rigorously tested by our engineering team in Italy.
Full Vertical Integration
Controlling every stage of production allows us to iterate faster, maintain the highest quality standards, and rapidly adapt our technology to client requirements.
01
Envelope Fabrication
We weld and assemble the urethane envelope in-house, ensuring airtight precision and structural integrity at every seam.
02
Propulsion Systems
Our unique fan motors are assembled and calibrated internally, optimized for low-speed, high-efficiency aerial operations.
03
3D-Printed Components
Critical structural and mechanical parts are designed in CAD and manufactured with industrial 3D printing for rapid prototyping and production.
04
Avionics & Electronics
CPU, GPU, and onboard computing are integrated with satellite communication modules including Starlink and Eutelsat connectivity.
05
Solar Power Integration
Organic solar panels are carefully mounted on the upper surface of the envelope, providing continuous energy for week-long autonomous missions.
06
Sensor Payload Systems
We configure and integrate mission-specific sensor payloads including gravimeters, magnetometers, LiDAR, SAR, and thermal cameras.
MANUFACTURING
From Raw Materials to Flight-Ready Aircraft
A look inside our production facility in Bellusco, where every component is fabricated, assembled, and prepared for deployment.
Envelope Welding & Assembly
The urethane envelope is precision-welded using specialized equipment to ensure gas-tight seams capable of sustaining helium pressure over extended missions. Each panel is individually inspected before integration.
3D Manufacturing
Structural brackets, motor mounts, sensor housings, and payload fixtures are designed in-house and produced with industrial-grade 3D printers, enabling rapid design iteration and lightweight, high-strength components.
Rigorous Testing at Every Stage
Every airship undergoes an extensive validation program before deployment. From individual component testing to full-scale flight trials, nothing leaves our facility without meeting our strict performance criteria.
Phase 01
Material Inspection
Every raw material batch — urethane sheets, electronic components, 3D printing filaments — is inspected and tested for compliance with our specifications before entering production.
Phase 02
Component Validation
Individual subsystems including motors, solar panels, communication modules, and sensor payloads undergo dedicated bench testing to verify performance under expected operating conditions.
Phase 03
Structural Integrity
The assembled envelope is subjected to pressure tests, seam integrity checks, and inflation cycles to ensure gas retention and structural resilience over extended periods.
Phase 04
Systems Integration
The complete avionics, propulsion, and power systems are tested together in a ground-based configuration to validate communication, control, and autonomous navigation capabilities.
Phase 05
Flight Testing
Full-scale flight trials validate aerodynamic performance, stability under wind conditions, autonomous navigation accuracy, and sensor data acquisition quality in real-world environments.
