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Service · phase 4

Production and serial manufacturing

Production turns a validated solution into a repeatable manufactured system — with the approved configuration unchanged.

Cluster of several round cargo parachutes over desert and mountains, the load just above the ground

From validation to repeatability

Once tested and validated, the solution is translated into a clear production configuration. It defines what must remain consistent throughout manufacturing: materials, components, dimensions, construction, assembly, interfaces and packing requirements. This gives the production team a clear reference for manufacturing the approved textile solution.

Depending on the solution, the production definition may include:

  • Approved materials and components.
  • Textile construction and assembly methods.
  • Dimensions and system geometry.
  • Platform interfaces and attachment points.
  • Folding, packing and storage requirements.
  • Deployment-related elements.
  • Inspection and documentation requirements.
  • Configuration control and traceability.

What happens in production

Activity covers textile cutting and sewing, assembly of textile and mechanical components, integration of deployment elements, folding, packing, inspection and preparation for delivery. Production may begin with an initial quantity, continue through defined manufacturing batches or support ongoing serial supply.

Why small changes matter

For lightweight, low-bulk systems even small changes to materials, construction or packing can affect integration and deployment behaviour. Other systems depend on specific containment, load, impact or deployment requirements. Configuration control is therefore part of production, not a downstream formality. The manufacturing process is built around the approved solution rather than applied as a standard production model.

Quality control within the process

Quality control remains part of that process. The objective is to manufacture each recovery or protection textile solution according to the approved technical direction and the function it was developed to perform. Depending on the solution, inspection may cover:

  • Material and component consistency.
  • Textile workmanship.
  • Dimensions and system layout.
  • Assembly and attachment points.
  • Folding, packing or storage.
  • Deployment-related elements.
  • Configuration records.
  • Final system condition before delivery.

What your team gets

Your team receives the validated recovery or protection textile solution manufactured according to its approved production configuration. This creates a controlled route from validated design to manufactured units ready for operational use or the next project stage. Depending on the project, this can include:

  • Initial production quantities.
  • Defined manufacturing batches.
  • Continued serial supply.
  • Controlled manufacturing records.
  • Configuration and traceability information where required.
  • Quality-control documentation.
  • Preparation for delivery and technical support.
White rectangular parachute canopy descending with a suspended load against a mountain backdrop

Why APCO

Producing a textile solution repeatedly while maintaining the approved construction and quality takes practical manufacturing experience.

The manufacturer develops and manufactures defense textile solutions for recovery and protection across defense, aerospace and unmanned systems: parachute recovery systems, airbags, deceleration mechanisms, deployment systems, ballistic and capture nets, precision airdrop solutions and custom textile-based applications. It operates a 3,200 m² production facility built for its manufacturing requirements, with in-house capabilities for skilled textile production, assembly, inspection and quality control.

Successful production begins long before manufacturing starts: with defining the requirements, developing the physical solution, testing its performance and carrying every approved decision into production.

Textile stretcher laid flat: blue fabric with black webbing, carry handles and buckles
Phase
Production
Standards
ISO / ASNIST 800-171

Technical data per manufacturer documentation from APCO Aviation Ltd , as of 2026-07-30.

Frequently asked

Asked in technical terms.

What does the production configuration define?

Everything that must stay constant through manufacturing: materials, components, dimensions, construction, assembly, interfaces and packing requirements, plus folding, packing and storage instructions, deployment-related elements, inspection and documentation requirements, and configuration control and traceability across the entire production run. That gives the production team an unambiguous reference for the approved solution.

Why are small manufacturing changes critical?

Because on lightweight, low-bulk systems even minor deviations in material, construction or packing alter integration and deployment behaviour. Other systems depend on specific containment, load, impact or deployment requirements. Configuration control is therefore part of production rather than a downstream formality to tick off.

When can a solution move into production?

A solution can normally move into production after the required prototype, testing and validation stages have been completed and the configuration has been approved for manufacturing. The production configuration then defines what must remain consistent throughout manufacturing and gives the production team a clear reference for the approved textile solution.

Does the manufacturer produce the solution itself?

Yes. The manufacturer produces the approved recovery or protection textile solution according to the agreed production requirements and quantities. Manufacturing can begin with an initial quantity and continue through defined batches or ongoing serial supply, in a 3,200 m² production facility built for its manufacturing requirements.

Does production include quality control?

Yes. The required quality-control activity is defined according to the textile solution, project requirements and intended use. Depending on the solution, inspection may cover material and component consistency, textile workmanship, dimensions and system layout, assembly and attachment points, folding, packing or storage, deployment-related elements, configuration records and final system condition before delivery.

What happens after production?

The manufactured solution can move into documentation, delivery, training where relevant and technical support after delivery. This creates a controlled route from validated design to manufactured units ready for operational use or the next project stage, backed by controlled manufacturing records and quality-control documentation.

Tell us what the system has to do.

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