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Projects: Prototype & Production

Learn more about the types of projects we're currently working on and examples of some prototypes and products we have recently completed.

  • 6m & 10m Prototype

    • 6m & 1Om Q/V frequency band prototype antennas
    • Designed and developed in Saskatoon using carbon fiber epoxy structures
    • First verification over satellite of high-frequency antenna technology
  • 10m Production

    • 1Om Q/V frequency band production antennas, pilot plant production online in early 2020
    • Producing 1Om antennas currently being deployed in the United States
  • 14m Prototype

    • 14m Q/V frequency band prototype antenna, designing next large aperture antenna
    • Expanding product line
    • 14m Q/V frequency band prototype antenna
    • Designing next large aperture antenna
    • Expanding product line

Engineering & Technology

Calian Composite's engineering capabilities embrace the use of industry-leading CAD, FEA, and metrology packages, as well as incorporate state-of-the-art methodologies to break new ground in our designs.

Our facility is equipped with <25μm 3D spatial positioning tools and high precision metrology equipment, allowing us to achieve tight tolerances and validate those tolerances are maintained during production.

We use high-precision software and lab equipment to verify our designs throughout the product lifecycle, in order to minimize costly redesigns and maximize product performance.

Material Testing Laboratory

  • Two-sided composite layup & infusion table
  • Ultrasonic test machine for void analysis
  • Viscosity, mass, and adhesion test equipment
  • Environmental chamber

Metrology & Precision

  • FARO & API laser trackers, FARO arm
  • Two 6-axis hexapod positioners
  • Custom built positioning fixturing

Jig & Tooling Manufacturing

  • In-house infused carbon epoxy tooling
  • Rapid prototyping and reverse engineering
  • Custom aluminum, steel and carbon composite jigs

CAD/CAE Capabilities

  • Industry-leading engineering modeling and simulation package
  • FEA for composites using ply-based or zone-based modeling
  • Static, dynamic, buckling, thermal, modal, and adhesive analyses
  • Flat pattern generation

Composites Manufacturing Facility Details

• Reconfigurable manufacturing facility with 30,000ft² manufacturing space

• 5-ton overhead & 1-ton jib cranes

• Large paint booth—14’ x 28’

• Post-cure oven—8’ x 8’ x 20’

• Product-specific post-of-use manufacturing instructions and part quality documentation and tracking

• Established list of qualified machine shop partners

• In-house capability for design and fabrication of customized production jigs


Calian Composites Overview


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Composites Process Options


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Composites vs Steel and Aluminum


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Ku V Band 1m Offset Reflector


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