Aerospace & Defence
Automation Solutions
MASK Control Systems designs and delivers automation solutions for aerospace and defence manufacturers across the UK and worldwide. Since 2013, we have engineered PLC control systems, control panels, and fully integrated automation solutions for safety-critical environments where precision and documentation matter as much as performance.
Our team understands the standards, the security requirements, and the zero-tolerance approach to defects that define this sector, and we build every project around them.

Why Aerospace & Defence Manufacturing Needs Specialized Automation
Aerospace and defence manufacturing operates under a level of scrutiny that few other sectors match. Systems must perform within extremely tight tolerances, and a single defect can carry consequences far beyond a production line.
Tight Tolerances & Zero Defect Consequence
In aerospace and defence, a single logic error or dimensional deviation can compromise human life or trigger massive mission failure. Systems must execute with deterministic precision every single cycle.
Exhaustive Qualification & Audit Cycles
Qualification and audit cycles run longer and deeper than in commercial sectors. Automation partners must deliver flawless FAT/SAT documentation that withstands intense prime contractor and MoD scrutiny.
Rigorous Configuration & Revision Control
Every system change requires formal configuration and revision control. A complete, unalterable historical log must exist for every component, wiring change, and software update throughout the equipment lifecycle.
Discretion & Strict Information Security
Many aerospace and defence projects involve classified or sensitive IP. Manufacturers require an engineering partner who treats confidentiality as foundational—from data encryption to vetted on-site personnel.

Supporting prime aerospace contractors, Tier-1 system suppliers, and defence programs across the UK with security-conscious, accredited engineering.
The UK Aerospace & Defence
Manufacturing Landscape
The UK aerospace and defence sector is one of the country's most established advanced manufacturing bases, supporting thousands of companies and tens of thousands of skilled engineers across design, production, and systems integration.
The South West of England, where MASK is headquartered in Cullompton, Devon, is a particularly dense engineering region for this sector—home to a large concentration of aerospace engineers and a long-standing supply chain built around major defence and aviation programs.
This sector faces a pronounced skills challenge. Security-cleared automation engineers are in short supply nationally, and many manufacturers find it difficult to recruit and retain the specialized talent needed to maintain and upgrade safety-critical control systems. That shortage is pushing more manufacturers toward experienced outsourced partners like MASK Control Systems who step in with the right documentation discipline and technical depth already in place.
Signs Your Aerospace or Defence Facility Needs Automation Support
Several recurring signals tell us an aerospace or defence facility is ready for an automation review before risks escalate into costly audit failures or line stoppages:
Aging End-of-Life PLC Systems
Legacy control systems are approaching end-of-life with no clear upgrade path or manufacturer spare parts availability.
Traceability & Audit Bottlenecks
Manual documentation and paper-based configuration logs struggle to keep pace with stringent defense traceability and audit demands.
Internal Engineering Capacity Deficits
In-house engineering teams lack the available hours or specific security clearances required to undertake new safety-critical automation programs.
Compliance Audit Documentation Gaps
Recent quality audits have flagged gaps or inconsistencies in control software change history, schematics, or component traceability.
Disproportionate Safety-Line Downtime
Unscheduled downtime on safety-critical assembly or testing lines creates unacceptable commercial penalties and operational risk exposure.
Obsolete Control Panel Components
Existing control cabinets rely on obsolete relays, discontinued drives, or unsupportable safety circuits with no direct vendor replacements.
Recognize any of these challenges in your facility?
An automation and control system review is worth prioritizing before audit or obsolescence issues escalate.
Our Aerospace & Defence
Automation Services
From safety-critical PLC logic to bespoke control cabinets and legacy modernization, we engineer end-to-end automation systems built around rigorous documentation, functional safety, and complete accountability.

PLC Programming & Control Systems
We develop robust control logic for safety critical aerospace and defence applications using industry standard platforms like Siemens, Mitsubishi, and Unitronics. Our programming approach emphasizes strict documentation and full traceability from the initial line of code to the final deployment. This ensures that every operation is completely auditable to meet rigorous industry compliance standards. We deliver solutions that prioritize both precise execution and comprehensive historical logging for your peace of mind.

Electrical Control Panel Design & Build
We specialize in engineering and manufacturing control panels that adhere to the stringent documentation and build quality expectations of the aerospace and defence sector. Every panel we build includes a complete, detailed record of all internal components, their sourcing, and the results of our rigorous testing process. This commitment to transparency ensures that your systems are reliable and easy to maintain throughout their entire lifecycle. We focus on structural integrity and precision to provide a foundation that supports your most critical manufacturing tasks.

Functional Safety Engineering
Our team performs detailed risk assessments and designs safety systems specifically for high consequence environments where precision and reliability are non negotiable. We ensure that every safety critical function is meticulously engineered, thoroughly tested, and extensively documented to meet the demanding standards of the aerospace industry. By prioritizing safety at the architectural level, we help you mitigate operational risks and protect your personnel and assets. Our documentation provides the evidence required for successful internal reviews and external audits.

Systems Integration
We manage the complex coordination of multi system environments where diverse equipment, control platforms, and safety systems must function as a single unit. This integration phase is often the most demanding part of an aerospace project, requiring deep technical expertise to ensure complete reliability across your infrastructure. Our end to end delivery model simplifies this process by keeping all coordination under a single accountable engineering partner. We unify your disparate production technologies to create a cohesive and highly efficient manufacturing process.

HMI & SCADA Development
We create secure, auditable operator interfaces and SCADA dashboards that provide your team with clear visibility into real time production performance. Our development process prioritizes user accessibility while maintaining the strict security protocols and access logging required in sensitive defence environments. We deliver intuitive control systems that simplify complex data without compromising the security or auditability of your operations. This empowers your operators to maintain high standards of efficiency and control throughout every production cycle.

Installation & Commissioning
We oversee the entire on site installation and commissioning phase, maintaining a precise documentation trail at every step of the deployment. This structured approach ensures that your project is ready for immediate internal sign off and provides all the necessary evidence for external audits upon completion. Our team manages the logistical challenges of integration, allowing you to focus on your core production goals. We remain on site to verify that everything performs to specifications, ensuring a smooth transition to full operation.

Legacy System Upgrades
We provide professional modernization services for outdated PLC and control hardware that has reached or is nearing its end of life. Our strategy focuses on upgrading your systems to current standards while minimizing any disruptions to your ongoing production schedule. By systematically addressing obsolescence risks, we extend the operational lifespan of your critical manufacturing lines. We ensure a seamless transition that restores reliability to your older infrastructure without compromising the performance of your current facility.
Specialized Ground Support (GSE) & Aircraft Tooling Automation
In addition to fixed manufacturing lines, MASK engineers high-reliability control systems and sensor telemetry for mobile airfield equipment and aircraft maintenance tooling (AMT).
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Ground Support Equipment (GSE) Automation
We engineer ruggedized, failsafe control systems for aviation ground handling and mobile flight-line equipment. Built to withstand extreme environmental conditions, heavy vibration, and continuous airfield duty cycles while providing precise load monitoring and operator interlocks.

Aircraft Maintenance Tooling (AMT)
Custom automated control systems and telemetry for aircraft maintenance tooling, engine overhaul stands, and structural proof-load testing rigs. Complete with certified load cell calibration, digital displacement recording, and automated test certification reporting.
Compliance, Traceability
& Security Built In
Aerospace and defence manufacturing runs on documented, auditable processes, and our systems are built to support that from day one.
We align our work with AS9100 and DEFCON standards, and we apply strict configuration and change management to every system revision, so a complete history exists for every modification made throughout a system's life. Our documentation is built to withstand the level of scrutiny that prime contractors and defence procurement bodies expect during audit.
We also take confidentiality seriously. Where a project involves sensitive or restricted information, we apply appropriate access controls and handling procedures throughout our engineering process, from initial design through to on-site commissioning.
AS9100 & DEFCON Aligned
Our quality management procedures and technical deliverables align directly with aerospace (AS9100) and UK Ministry of Defence procurement expectations.
ISO Accredited Quality
Holding ISO 9001, ISO 17020, and ISO 17025 accreditations, we bring formal quality assurance, calibration rigor, and inspection discipline to every build.
Rigorous Configuration Control
Every logic revision, wiring modification, and component change is captured in formal engineering change orders (ECO) with complete audit histories.
Information Security & Discretion
Strict data handling, NDAs, and physical security measures protect proprietary aviation IP, military specifications, and sensitive program details.
Supporting Aerospace & Defence Manufacturers Worldwide
We are headquartered in Cullompton, Devon, in the United Kingdom, and we apply the same engineering discipline and documentation standards to aerospace and defence projects across three continents.
Whether your facility is based in the UK, mainland Europe, North America, or the Middle East, you receive the same rigorous process, the same certified quality management systems, and the same commitment to long-term lifecycle support.
Rapid on-site emergency engineering, commissioning, and scheduled maintenance across the UK defence corridor and European manufacturing hubs.
Full SAT commissioning, turn-key FAT validation, and remote telemetry support for multinational aviation suppliers and defence facilities.
Air-gapped architecture design, encrypted VPN gateways, and role-based remote diagnostics adhering to strict client cyber policies.
How We Work
We follow a structured, documented process on every aerospace and defence project to guarantee total traceability and compliance:
Consultation & Audit
We assess your technical specifications, security parameters, compliance obligations, and project feasibility before engineering begins.
System Design
Our engineers develop comprehensive CAD schematics, functional design specifications (FDS), and safety architectures aligned with your standards.
Build & In-House FAT
We manufacture panels and build control logic in-house, completing 100% rigorous Factory Acceptance Testing with complete documentation prior to dispatch.
Commissioning & SAT
We install on-site, integrate with existing plant systems, and execute structured Site Acceptance Testing while maintaining complete audit trails.
Lifecycle Support
We provide ongoing preventative servicing, remote telemetry, and long-term technical support to keep your systems reliable and fully compliant.
Why Manufacturers Choose MASK for
Aerospace & Defence Automation
We hold ISO 9001, ISO 17020, and ISO 17025 certifications, and we bring that same quality management discipline to every aerospace and defence project. Our team works across Siemens, Mitsubishi, Unitronics, Allen-Bradley, and Omron platforms, so we recommend the right technology for your application rather than defaulting to a single vendor's equipment.
We manage every project end to end, from initial design through build, installation, commissioning, and ongoing support, so you work with one accountable engineering partner rather than coordinating multiple contractors.
As the shortage of security-cleared, sector-experienced automation engineers continues to affect the industry, we act as an experienced outsourced team who already understands the standards, the documentation, and the scrutiny this sector demands.
Tri-Certified Quality Rigor
ISO 9001 (Quality), ISO 17020 (Inspection), and ISO 17025 (Testing/Calibration) standards integrated directly into our panel manufacturing and code testing protocols.
Vendor-Agnostic Objectivity
Deep engineering capability across Siemens SIMATIC S7, Mitsubishi MELSEC, Unitronics, Rockwell Allen-Bradley, and Omron platforms. We select what fits your application best.
Single Accountable Partner
From concept and panel build to on-site commissioning and 24/7 technical breakdown support, we eliminate multi-vendor friction and finger-pointing.
Overcoming Sector Skills Gaps
Ready-to-deploy engineering specialists possessing the necessary technical depth, safety credentials, and sector familiarity required by prime defense contractors.
Frequently Asked Questions
Key questions aerospace and defence manufacturers ask when evaluating MASK Control Systems as their automation partner:
What certifications does MASK hold for aerospace and defence work?
Can you work on classified or security-sensitive projects?
How do you handle configuration and change control on safety-critical systems?
Do you support legacy PLC systems that are nearing end-of-life?
Do you deliver aerospace and defence automation projects outside the UK?
Explore Other Industries We Serve
In addition to aerospace and defence, MASK engineers bespoke control and automation systems across diverse high-performance industrial sectors:
Get In Touch With Our Aerospace & Defence Engineers
If you are planning an aerospace or defence automation project, or you need to modernize a legacy control system, our team is ready to help. Explore our other industry sectors or contact us directly to discuss your requirements.
