Design & Manufacture

We offer a solution-focused design and manufacturing capability, developing concepts into mature designs and delivering components and assemblies that meet the most stringent quality standards.

Design & Manufacturing Solutions


Integrating product design and process planning to deliver high-quality, cost-effective solutions.




Offering a UK-based production capability that ensures security, flexibility and convenience.




Dedicated rapid prototyping and engineering solutions for PCB, enclosure and cable harness designs.



What we offer

Effective solutions

Developing solutions that make a real difference to your programmes and business


Passionate belief and commitment to quality.


Cyber essentials accredited, with MOD cleared staff available.


Responding to your needs, reacting to evolving technology


An adaptable approach to design, engineering, procurement and manufacturing.


Combining a full range of capabilities with the low overheads of an SME.

An assured service

We want to ensure that you always get a consistently high standard of service. In addition to our other accreditations, we were the first company in Europe to gain NADCAP certification for both AC7120 (Circuit card assembly), and AC7121 (Cable & Harness).
  • Armed Forces Covenant Employer Recognition
  • AS9100D – Quality Management in aerospace sector
  • Cyber Essentials Plus – Cyber Security
  • ISO14001:2015 – Environmental Management
  • ISO9001:2015 – Quality Management System
  • NADCAP AC7120 – Circuit Card Assembly
  • NADCAP AC7121 – Cable & Harness
  • OHSAS 18001:2007 – Occupational Health & Safety Management

Design Capabilities

Starting from an initial concept or a detailed specification, we provide a comprehensive design service that incorporates electronic, electro-mechanical, network, manufacturing, maritime, systems and software engineering.

Electronic design, including circuit development and PCB design.
Electro-mechanical design, including use of Inventor 3D Computer Aided Design.
Software development, including software integration, graphic user interface design, driver interfaces and server configuration.
Protoype design, including on-site secure test facilities.
Systems Engineering, including use of INCOSE trained staff and methodologies and Product Lifecycle Management.

Engineering Capabilities

We offer a dedicated Technology Centre that provides a Design for Manufacture service to optimize product and system design. We will work with you to integrate product design and process planning into one common activity, structured to ensure your project can be easily and economically manufactured.

Optimising all manufacturing functions, including fabrication, assembly, test, procurement, shipping, service and support.
Ensuring the best cost, quality, reliability, regulatory compliance, safety, time-to-market, and customer satisfaction.
Offering a formal new product introduction process with clear documentation and review cycles.
Materials support for all levels of PCB, cable assembly and box build.
JSTD-001, IPC-A-610, IPC-WHMA-A-620 certified personnel.

Manufacturing Capabilities

Our UK-based manufacturing facilities offer a secure, comprehensive and flexible service for the aerospace, defence and marine sectors, capable of developing prototypes and delivering low to medium volume production runs quickly and at a low cost.

Over 50 years’ experience in the design, manufacture, supply and repair of aircraft looms and specialised subsea cables.

Offering a range of PCB services, from single board prototypes to high volume production.

  • NADCAP AC7120 accreditation for PCB assembly
  • IPC-A-610 operatives
  • Three surface mount lines and conventional through hole
  • Leaded and lead-free (SMT, TH and Wave)
  • BGA and X-Ray inspection capable
  • Conformal coating
  • Environmental Stress Screening
  • Automatic Optical Inspection

Manufacturing a range of bespoke structures for the defence and aerospace markets.

  • Sheet metalwork folding & punching up.
  • TIG and Spot welding (coded welders)
  • Precision milling and turning
  • Painting and finishing – Wet, dry, powder, silk screening, engraving, plate finishing and dip-brazing

Fabrication of complex panels and boxes for aerospace and military applications.

  • Sub-system assembly
  • Electro-mechanical assembly
  • All operatives trained to JSTD-001, IPC-A-610 and IPC-WHMA-A-620 Level 3 standards
  • Manufacture of individual prototypes to production quantities
  • Programme and procurement management
  • Flexible, scalable capacity and obsolescence management
  • Cable and wiring solutions
  • Fabrication and finishing
  • Bespoke test solutions

Sharing in Growth

STS Defence is part of the Sharing in Growth programme, a Government initiative to raise the capability of UK aerospace suppliers by sharing best-practice.

The scheme provides tailored training and development programmes which cover all relevant disciplines such as lean operations, manufacturing processes, purchasing, cost modelling and leadership.

For STS Defence, Sharing in Growth has accelerated our Continuous Improvement journey and delivered sustainable benefits, not only in manufacturing efficiencies but also in developing leadership skills and pulling people together to deliver great customer satisfaction.

Add value to your manufacturing tasks

Because we work across the product life-cycle, manufacturing activities benefit from research capabilities and platform integration expertise, enhancing product development and reducing the risks for our manufacturing customers.

Case studies

Containerised communications for HMS Protector

Developing a military communications solution for the Royal Navy's ice patrol vessel

Engine cases for Vector Aerospace

Providing a secure voice and data communications network for boarding operations to improve situational awareness

Configurable Communications Masts

High reliability and configurable masts for maritime applications

Find out more

Do you have a requirement you’d like to discuss with us? Call on +44 (0) 2392 584222 or email below.