Starling's Expertise in Lightweight Drone Structures

Pioneering Advanced Material Design for
Unmatched UAV Performance

At Starling, we leverage cutting-edge materials and engineering expertise to create lightweight, strong, and durable drone structures. Our mastery of composite materials, including carbon fiber and Rohacell, enables us to design the Pathfinder FX-VTOL, a high-performance drone weighing only 6 kg yet capable of flying for over 3 hours and reaching speeds of over 160 km/h.

Experience the Power of Lightweight Innovation with Starling

From extended flight times to enhanced durability, our expertise in lightweight structures elevates drone performance across industries. Explore how Starling’s material innovations power the Pathfinder FX-VTOL.

Advanced Materials for
Superior Performance

Carbon Fiber
  • High Strength-to-Weight Ratio: Provides exceptional durability while minimizing weight for extended flight times.
  • Enhanced Durability: Withstands extreme operational conditions, including high speeds and adverse weather.
  • Aerodynamic Optimization: Smooth, lightweight surfaces reduce drag, improving efficiency and endurance.
Rohacell Core
  • Lightweight Rigidity: This advanced foam material offers excellent structural support with minimal weight.
  • Impact Resistance: Absorbs shocks and vibrations to protect critical components during operations.
  • Thermal Stability: Performs reliably in varying environmental conditions, from extreme heat to cold.

Engineering
Excellence

Integrated Design Philosophy
  • Structural Optimization: Every gram of the Pathfinder’s structure is designed for maximum efficiency, balancing strength, weight, and performance.
  • Load Distribution: Smart design ensures even weight distribution, enhancing stability and flight dynamics.
  • Modular Build: The lightweight design supports payload adaptability, allowing seamless integration of sensors and cameras.
Precision Manufacturing
  • Aerospace-Grade Processes: Employing advanced fabrication techniques for precision and consistency.
  • Rigorously Tested: Each component undergoes extensive testing to ensure reliability and durability in real-world conditions.

Pathfinder FX-VTOL: A Testament to
Lightweight Innovation

Unmatched Performance Metrics

Weight

Only 6 kg, enabling efficient transport and deployment.

Endurance

Over 3 hours of continuous flight on a single battery.

Speed

Reaches top speeds exceeding 160 km/h, ideal for rapid deployment and mission coverage.

Applications Across Industries

Defense

Lightweight, long-endurance design supports extended surveillance and reconnaissance missions.

Infrastructure Inspections:

Cover extensive areas efficiently without sacrificing detail or accuracy.

Emergency Response

Rapid deployment with high durability ensures reliable performance in critical situations.

  • Extended Flight Times

    By reducing structural weight, we maximize energy efficiency, enabling drones like the Pathfinder to achieve industry-leading endurance.

  • Increased Payload Capacity

    Our advanced materials allow for the inclusion of heavier payloads, such as EO/IR cameras and specialized sensors, without compromising performance.

  • Enhanced Durability

    Strong, impact-resistant structures provide resilience in demanding environments, ensuring operational reliability.

  • Sustainable Innovation

    Using advanced composites minimizes material waste while delivering long-lasting, reusable designs.

Why Starling Leads in
Lightweight Drone Design

Innovative Materials Expertise
  •  Decades of experience working with carbon fiber, Rohacell, and other composites.
American Craftsmanship
  • Designed, built, and rigorously tested in Southern California to meet the highest standards.
Proven Performance:
  • The Pathfinder FX-VTOL exemplifies our commitment to lightweight, high-performance UAV solutions.