From Prototype to Production: Wilder Industries Highlights the Manufacturing Challenge Facing Drone and Autonomous Systems Companies
As demand for drones and autonomous platforms grows, scalable manufacturing, automation and production-ready design are becoming increasingly critical to bringing next-generation systems to market.
DALLAS, Texas — [September 25, 2026] — As aerospace and defense companies accelerate development of drones, unmanned aircraft and autonomous systems, Wilder Industries is highlighting a challenge that extends beyond designing the technology itself: building a manufacturing strategy capable of producing it efficiently, consistently and at scale.
The next generation of aerospace companies is moving quickly. New platforms are being designed, tested and refined at an unprecedented pace, but transitioning a successful prototype into repeatable production introduces an entirely different set of challenges.
Part geometry, material selection, tooling, machining requirements, assembly processes and opportunities for automation can all affect whether a product that performs successfully in development can also be manufactured efficiently at higher volumes.
For companies planning to scale, Wilder Industries believes manufacturing strategy should begin long before full-rate production.
“Building a successful prototype is an important milestone, but it doesn’t automatically mean a product is ready to scale,” said Will Wilder, Founder & CEO of Wilder Industries. “The companies that think about manufacturing and automation early have an opportunity to design production into the platform from the beginning. That can make a significant difference when demand increases and the program needs to move from building a handful of systems to building them consistently at scale.”
Designing for Production From the Beginning
Drone and autonomous-system manufacturers often operate under aggressive development timelines, particularly when serving rapidly evolving commercial and defense markets.
During early development, engineering teams are naturally focused on performance, weight, functionality and proving the platform. But decisions made during this stage can have significant consequences later in production.
Design for Manufacturing (DFM) brings manufacturing considerations into the engineering process earlier, helping teams evaluate how components will actually be formed, machined, assembled and produced.
Design for Automation (DFA) takes that process further by identifying how a platform and its production processes can be designed to support robotics and automation as volumes increase.
Together, these disciplines can help manufacturers identify potential production constraints before they become costly problems.
“Manufacturing shouldn’t be something you figure out after the product has already been designed,” Will said. “If you know a program needs to scale, you should be thinking about how parts will be manufactured, how assemblies come together and where automation makes sense while the product is still being engineered.”
Building a More Scalable Manufacturing Model
Wilder Industries brings together complementary capabilities through Hughes Bros. Aircrafters and Wilder Systems.
Hughes provides detailed part manufacturing and DFM expertise alongside capabilities including sheet metal forming and hard metal machining. Wilder Systems designs, builds and deploys robots and automation systems for manufacturers.
Together, these capabilities allow Wilder Industries to approach aerospace production as an interconnected process spanning:
- Design for Manufacturing (DFM)
- Design for Automation (DFA)
- Detailed part manufacturing
- Sheet metal forming
- Hard metal machining
- Robotic and automated manufacturing systems
This structure allows manufacturing and automation considerations to work together rather than being addressed independently later in the production process.
Wilder Industries’ current portfolio combines established aerospace manufacturing capabilities with next-generation automation. Wilder Systems’ robotic platforms support processes including drilling, match drilling, sanding and inspection, while Hughes Bros. Aircrafters brings decades of experience producing precision airframe sheet metal details and assemblies.
Preparing Autonomous Systems for Higher-Rate Production
As drone and autonomous-system programs mature, production requirements can change quickly.
Processes that work when producing a limited number of prototypes may become inefficient as volumes increase. Manual processes can introduce capacity constraints. Part designs can create unnecessary manufacturing complexity. Production sequences that were manageable at low volume may become difficult to repeat efficiently.
Building scalability into the manufacturing strategy earlier can help companies prepare for that transition.
Automation is an important component of that strategy, but Wilder Industries views automation as more than simply adding a robot to an existing process.
The company’s approach focuses on evaluating the product and production environment together to determine where automation can improve repeatability, productivity and scalability.
Wilder Systems recently demonstrated that approach through the implementation of an automated robotic sanding system at Hughes Bros. Aircrafters’ South Gate, California facility. The system automates a labor-intensive aerospace finishing process while improving repeatability and production efficiency.
“The goal isn’t automation for automation’s sake,” Will said. “The goal is to build the right manufacturing system for the product. Sometimes that means changing how a component is designed. Sometimes it means improving the manufacturing process. Sometimes automation is the answer. The real opportunity comes when you can evaluate all of those things together.”
Manufacturing the Next Generation of Aerospace Systems
The continued growth of drones and autonomous systems represents an opportunity not only for technology developers, but also for the aerospace manufacturing base supporting them.
Wilder Industries is building its organization around that opportunity, combining established aerospace production capabilities with engineering and automation expertise to support companies as they move from development toward scalable manufacturing.
For drone and autonomous-system companies, the message is straightforward: production readiness should begin before production does.
“Some of the most exciting aerospace technology being developed today is coming from companies that are moving incredibly fast,” Will said. “Our role is to help make sure manufacturing can move just as fast. If we can bring DFM, DFA, production and automation together earlier, we can help the next generation of aerospace companies build platforms that aren’t just innovative—they’re ready to scale.”
About Wilder Industries
Wilder Industries is the parent holding company for American aerospace manufacturing and automation businesses focused on modernizing the defense and commercial aerospace supply chain. Through Wilder Systems, the organization designs, builds and deploys robotic and automation systems for manufacturers. Through Hughes Bros. Aircrafters, Wilder Industries provides detailed aerospace part manufacturing, Design for Manufacturing, sheet metal forming, hard metal machining and airframe production capabilities.
Together, Wilder Industries provides end-to-end Design for Manufacturing (DFM), Design for Automation (DFA), production and automation solutions, with automation as a core focus area.
Media Contact
Ron Castro
Director Sales & Business Development | Wilder Systems Inc
Mobile: 206-953-9887
Dallas, TX
Wilder Industries