Aerospace & Defense Hardware Solutions

USL provides digital engineering services focused on aerospace, defense, and high-reliability hardware applications. We specialize in converting physical components—particularly legacy, obsolete, or mission-critical parts—into precise digital assets through advanced 3D scanning, metrology, and modeling. This core capability supports secure, domestic sustainment, obsolescence mitigation, and supply chain resilience for federal agencies, primes, and small business partners.

Our approach emphasizes building long-term relationships with government customers, suppliers, and small businesses while strengthening the U.S. industrial base through innovative digital processes.

Core Services

Digital Engineering and Hardware Digitization

• On-site or controlled-environment 3D scanning and reverse engineering to capture accurate geometry of physical hardware
• Generation of clean CAD models, technical data packages (TDPs), STEP/IGES files, and digital twins
• Rapid digital conversion that enables downstream manufacturing, prototyping, simulation, and predictive maintenance without original drawings or foreign dependencies

Program and Supply Chain Management

• End-to-end oversight of digital-to-production workflows, ensuring compliance, on-time delivery, and cost control
• Risk assessment focused on obsolescence and supply chain vulnerabilities, with mitigation through domestic digital asset creation
• Secure logistics and chain-of-custody management for complex components

Advanced Manufacturing Integration

• Seamless transition from digital models to domestic production using additive manufacturing, CNC machining, and composite methods
• Application of lean principles to optimize cycles from digitized data to finished parts
• Systems integration support for interoperability across platforms, informed by precise digital representations

Maintenance, Repair, and Overhaul (MRO) and Spare Parts Sustainment

• Tailored solutions for aircraft, UAVs, military vehicles, and ship systems, leveraging digital twins for extended service life
• Predictive maintenance strategies enhanced by accurate digital models of components
• Repair and overhaul of hardware guided by newly created or refreshed technical data

Engineering and Development Support

• R&D applied to digital transformation of legacy systems, materials qualification, and avionics/electronics sustainment
• Rapid prototyping and testing accelerated by high-fidelity digital files
• Innovation in digital asset management to deliver cost savings and performance improvements

Integrated Logistics Support (ILS)

• Logistics planning optimized through digital inventory modeling and forecasting
• Secure storage, transportation, and distribution solutions for digitized and physical assets

Compliance and Export Control

Expert guidance on ITAR, EAR, DFARS, CMMC Level 2, and JCP requirements.

Mil-Spec Packaging and Logistic Services

Ensuring the safe and secure delivery of your products is paramount. Our packaging and shipping services are designed to meet the unique needs of the military, aerospace, and defense sectors:

• Custom Packaging Solutions: We provide packaging that meets MIL-SPEC requirements, protecting your products from environmental and physical damage during transit. Our solutions include cushioning, sealing, and marking that comply with all relevant standards
• Secure Shipping: Our logistics team is experienced in handling sensitive and high-value shipments. We offer secure, trackable shipping options that ensure your products arrive safely and on time, no matter where they are needed

Manufacturing Solutions for the Aerospace and Defense Industry

Precision and quality are non-negotiable in the aerospace and defense industries. USL offers manufacturing solutions designed to meet your exact specifications:

• Custom manufacturing solutions: From precision machining to metal processing, we manufacture highly engineered components. Our end-to-end services work to develop custom manufacturing solutions that meet project expectations
• Quality Assurance: We are committed to maintaining the highest standards of quality. Our rigorous quality control processes ensure that every product meets or exceeds industry specifications, giving you confidence in the performance and reliability of our solutions

Industry Certifications

JCP and CMMC Compliance

All manufacturing partners are ISO 9001, AS9100, and ITAR Compliant

NAICS Codes

• 541330
• 541370
• 541340
• 541690
• 541990
• 336413
• 332994
• 336992
• 336611

Trusted Partners