CASE STUDY: Avior Labs

Avior Labs has advanced the Elevation, a small commercial vertical take-off and landing VTOL drone, from early functionality to an industrialisation phase. With support from the AISI, the fuselage was redesigned using a hybrid composite and Expanded Polypropylene EPP method, cutting weight, cost, and production time.

The next phase focused on three priorities: embedding datalink antennas to replace commercial ones, upgrading the tail to a moulded shell with integrated control surfaces, and applying the same construction method to the outer wings. These improvements enhanced manufacturability and positioned the drone for greater competitiveness in both local and export markets.

To deliver these goals, Avior Labs partnered with Lightweight Structures, a South African composite engineering specialist, and LambdaG, an advanced antenna design company. Avior Labs, as project lead and IP holder, provided unmanned aerial vehicle UAV systems expertise; Lightweight Structures contributed manufacturing capacity; and LambdaG developed and integrated conformal antennas into the composite fuselage. All objectives were met, with only a minor delay for antenna design refinement. The project strengthened Elevation’s readiness for commercialisation while deepening long-term R&D and manufacturing collaboration, supporting job retention and laying the groundwork for growth.

Founded in 2019, Avior Labs develops high-efficiency UAVs for applications in health, agriculture, security, environmental monitoring, and humanitarian operations. In 2021, it formalised its partnership with Lightweight Structures to produce Elevation’s structural components, positioning the UAV as a cost-effective platform with longer endurance than multirotor drones and a better price point than international competitors. With production expected to scale from 2024, the project highlighted the importance of innovative and scalable manufacturing processes.

A key innovation was the integration of conformal embedded antennas into the hybrid EPP/composite airframe, reducing drag and improving structural efficiency compared to traditional antennas. LambdaG developed prototypes operating in the 900 MHz IMT band, with future plans to expand into C-band for larger UAVs. This advancement enhances South Africa’s aerospace capabilities, enabling participation in global UAV supply chains with cost-effective, high-performance systems.

The broader goals include job creation and progress into wider aerospace markets.