Aerosystems expands its Exton facility to develop software and hardware aimed at replacing jet pilots.

Innovative Aerosystems Inc. has made significant strides in the aerospace manufacturing sector with the recent expansion of its facility located in Chester County’s Great Valley. This state-of-the-art facility is staffed by approximately 200 engineers, technicians, and support personnel who are dedicated to the design, production, and sale of advanced cockpit computers and navigation systems for various clients, including Air Force One, Boeing, Lockheed Martin, Amazon, and FedEx, alongside military services both domestically and internationally.

Established in 1987, Innovative Aerosystems has experienced notable growth, having doubled its workforce in the past three years. CEO Shahram Askarpour announced plans to recruit an additional 100 engineers and technicians to spearhead the development of self-flying aircraft systems as part of the company’s commitment to modernizing the current air fleet.

The company is actively participating in the resurgence of domestic manufacturing, or “reshoring,” as it opts to produce most of its components locally at its Exton, Pennsylvania, plant. This facility has become crucial for the manufacture of parts, while only a small array of mass-produced aluminum components are outsourced to local machine shops. The initiative aligns with an uptick in defense spending and a projected increase in civilian air travel demand, both factors that are expected to sustain and drive growth for years to come.

Askarpour, who succeeded the late founder Geoffrey S.M. Hedrick as CEO in 2022, has overseen substantial revenues and profit increases, having tripled revenues and quadrupled profits in recent years. The company’s investments include a recent million acquisition of several product lines from Honeywell, further consolidating its operations within the United States.

A key advantage for Innovative Aerosystems is its commitment to in-house production. The company manages all aspects of its manufacturing processes, including the creation of circuit boards, an approach that has allowed it to maintain consistent quality control and mitigate the challenges posed by global supply chain disruptions, particularly during the COVID-19 pandemic.

Askarpour emphasizes the importance of maintaining high safety standards, noting that Innovative Aerosystems has never faced an FAA citation related to faulty parts. This robust safety record positions the company as a reliable partner for military and commercial clients alike.

Innovative Aerosystems operates within a competitive landscape, with other aerospace firms, such as Triumph Group and Ametek, also vying for military contracts. However, the volatile nature of defense contracts necessitates a strategic outlook, as military business can fluctuate based on government decisions and external factors.

Overall, the company’s proactive approach to enhancing its operational capabilities, combined with a workforce that values experience, positions it as a significant player in both the aerospace and defense sectors. As it continues to grow, Innovative Aerosystems is redefining what it means to be an American manufacturer in the modern era.