END-TO-END
MANUFACTURNIG - FROM
DESIGN TO DELIVERY

DESIGN INPUT & REQUIREMENTS DRIVEN DEVELOPMEnt with ergonomics review (physiotherapist in house) to optimise load distribution.
DESIGN FOR MANUFACTURING FOR LOAD-BEARING TEXTILES (SEAMS, REINFORCEMENTS, TOLERANCES), RELIABLE, SCALABLE AND AT TARGET COST
CAD PATTERNING & GRADING (GERBER COMPATIBLE)
MATERIALS & COMPLIANCE GUIDANCE (IRR/FR, REACH, NATO LABELS)
TECH PACK: BOM, CUT MAPS, STITCH PROGRAMS, QC PLAN (HANDOVER TO PROTOTYPING IN 3-5 DAYS WHEN MATERIALS AVAILABLE)
Rapid sample turnaround based on legacy sample, sketch, or CAD
CAD-to-cut compatibility with Gerber formats
Programme support from R&D to field test stage
Traceability begins from first iteration
CNC & Die Cutting with +/-0.5 mm precision on IRR and FR fabrics.
Digital nesting with live material yield monitoring
Multi-layer stack cutting for increased throughput
SERIALISED CUT FILE MANAGEMENT FOR PROJECT-LEVEL TRACEABILITY WITH SECURE FILE HANDLING.
Modular sewing cells tailored to reinforced and load-bearing constructions
SPECIALISED OPERATORS TRAINED ON HELMET SYSTEMS, VESTS, POUCHES, AND CARRIERS.
COMPLIANCE SEWING WITH IRR THREAD AND FR STITCH SPECS APPLIED PER CLIENT REQUIREMENT.
VOLUME SCALE-UP THANKS TO OPTIMISED OPERATOR WORKFLOWS TO ENABLE RAPID RAMP-UP FOR LARGE ORDERS.
IRR COMPLIANT SOURCING - WEBBING, MIL-SPEC HARDWARE, ABD CUSTOM HELMET FASTENERS SOURCED TO NATO STANDARDS.
Controlled STOCKROOM AND SECURE STORAGE FRO CLIENT-SUPPLIED OR PRE-APPROVED MATERIALS.
INTEGRATED LABELLING WITH NATO-STANDARD UID AND BARCODES FOR FULL TRACEABILITY.
QUALITY ASSURANCE - FIRST-PASS YIELD TRACKING REDUCES HANDLING AND REWORK.
Tailored assembly with lines configured per product family or programme.
final inspection, aql 1.0 standard with visual, tensile and fixture specific checks.
nato-compliant dispatch with packing, serialisation and full documentation.
secure shipping and classified handling under nato protocols.
Technology

SMART MANUFACTURING FOR MODERN DEFENCE. FROM DESIGN TO PACKED PALLET, EVERY STAGE IS DIGITALLY CONNECTED.

01
CNC Laser & Die Cutting
AUTOMATED GERBER WORKFLOWS DRIVE PRECISE MULTI-LAYER CUTS ON IRR AND FR FABRICS, WITH +/- 0.5 MM TOLERANCE FOR MAXIMUM YIELD.
02
Modular Sewing Cells
FLEXIBLE PRODUCTION LINES DESIGNED FOR RAPID CHANGEOVERS. PARTNER-ENABLED DIGITAL STITCH PROGRAMMES AND OPERATOR TRACKING, WITH IN-HOUSE INTEGRATION UNDERWAY
03
Digital Shop-Floor Control
DASHBOARDS TRACK ORDER STATUS, MATERIAL YIELD, AND DELIVERY FORECASTS, GIVING CLIENTS VISIBILITY AND CONFIDENCE AT EVERY STAGE.
04
AI-Assisted Quoting & Nesting
MACHINE-LEARNING TOOLS OPTIMISE MATERIAL USE AND PROVIDE FAST, DATA-BACKED COSTING - REDUCING WASTE EVEN ON LOW-VOLUME, HIGH-COMPLEXITY RUNS.
05
Secure Data Environment
ISO 27001 protocols govern file handling, NDA repositories, and encrypted client portals, ensuring classified designs remain protected.
01
CNC Laser & Die Cutting
AUTOMATED GERBER WORKFLOWS DRIVE PRECISE MULTI-LAYER CUTS ON IRR AND FR FABRICS, WITH +/- 0.5 MM TOLERANCE FOR MAXIMUM YIELD.
02
Modular Sewing Cells
FLEXIBLE PRODUCTION LINES DESIGNED FOR RAPID CHANGEOVERS. PARTNER-ENABLED DIGITAL STITCH PROGRAMMES AND OPERATOR TRACKING, WITH IN-HOUSE INTEGRATION UNDERWAY
03
Digital Shop-Floor Control
DASHBOARDS TRACK ORDER STATUS, MATERIAL YIELD, AND DELIVERY FORECASTS, GIVING CLIENTS VISIBILITY AND CONFIDENCE AT EVERY STAGE.
04
AI-Assisted Quoting & Nesting
MACHINE-LEARNING TOOLS OPTIMISE MATERIAL USE AND PROVIDE FAST, DATA-BACKED COSTING - REDUCING WASTE EVEN ON LOW-VOLUME, HIGH-COMPLEXITY RUNS.
05
Secure Data Environment
ISO 27001 protocols govern file handling, NDA repositories, and encrypted client portals, ensuring classified designs remain protected.
PROJECTS:

IRR Helmet Covers

99.4 %
FPY
12 k
units for a European
Tier 1 OEM
8
week rollout from
prototype to delivery

Tactical Vest Kits

8 k
complete kits for a global programme
98%
OTIF across
NATO
Deliveries supported by integrated QA and NATO-standard labelling

Plate Carrier Retrofit

5-day
prototyping cycle - rapid turnaround from legacy design to new spec
25%
material saving achieved through re-engineering and digital nesting
NDA
Legacy system overhaul under NDA

Capabilities

Production in Europe

Manufacturing is anchored in our EU HQ in the Czech Republic, supported by a cost-competitive facility in Ukraine. The structure gives clients tariff-free access to European supply chains , ISO-audited processes, and rapid logistics to any NATO destinations.Across both sites, over 250 operators run CNC cutting, modular sewing cells, and digitally managed assembly lines - ensuring repeatable quality with full EU origin certifications where required.

Hybrid Onshore / Offshore

HYBRID EU / UKRAINE MODELFor high volumes or cost-sensitive projects, we offer a hybrid approach:Core, security-critical steps (cutting, QA, final assembly) remain in our Czech HQ under ISO and NATO protocolsLabour-intensive sub tasks are carried out in our Ukraine facility under controlled digital workflowsEvery lot is re-inspected on return, preserving EU compliance, REACH documentation, and full serialised traceability

Full-Service Partner

We manage the full lifecycle - starting with design support and requirements capture, translating client concepts into CAD-ready files. From there, we deliver rapid prototyping, material sourcing (IRR fabric, mil spec hardware), production planning, inline QA, NATO standard labelling, secure packing, and classified dispatch under NDA. Clients benefit from a single accountable partner with order visibility and proven KPIs, including 98% OTIF and 96% First Pass Yield. Complex defence requirements are streamlined into contract-ready product deliveries.

Digital Traceability & Compliance

We provide full documentation for EU and NATO buyers, including ISO 9001 / ISO 27001 certificates, REACH material logs, and NATO-compliant labelling.We are developing expanded digital traceability systems to capture production data and link it directly with compliance records - clear audit trail and reduced paperwork.

Rapid Response & Field Mod Support

Dedicated pilot lines enable sample turnaround within 3-5 days when materials are available, letting programme teams test modifications quickly without waiting for full production slots. With surge capacity across our Czech and Ukrainian sites, we can scale rapidly - for example producing 5,000 - 10,000 units within 6-8 weeks, depending on complexity. This ensures we can move from prototype to deployment under real-world timelines.

Compliance

Built to Spec. Supported by
Certification

ISO 9001:2015 QMS & ISO 27001:2022 ISMS audited annually.
REACH compliance with Article 2(3) defense exemption workflow where required.
CE marking capability for soft-good PPE (EN ISO 13688, EN 343, etc.).
Digital Product Passport roadmap in place ahead of 2030 EU mandate.
Digital Product Passport roadmap in place ahead of 2030 EU mandate.
Secure protocols: encrypted file exchange, role-based access, NDA as standard.
NATO packaging (STANAG 4280) and UID labelling ready.

Our quality management is
aligned with
AS9001. Our IT keeps
your
data safe.