Industries We Serve

Steelhead Composites supports a range of aerospace, space, and defense missions where performance, safety, and reliability are mission-critical.

  • Launch Vehicle Propulsion Systems
  • Spacecraft Propulsion & Maneuvering
  • Satellite Systems
  • Unmanned Aerial Vehicles (UAVs)
  • Crewed Aircraft & Life Support Systems
  • Ground Support & Tank Farms
  • Stage Separation & Actuation Systems
  • Defense & Military Systems

In aerospace, space, and defense applications, weight, safety, and reliability are mission-critical. Steelhead Composites designs and manufactures advanced composite overwrapped pressure vessels (COPVs) that meet the toughest certification and performance requirements. Our small-format vessels serve UAVs, satellites, and breathing oxygen systems, while our large-capacity tanks support launch propulsion, spacecraft maneuvering, and ground operations. 

With expertise in AS9100, ISO, and DOT compliance, we deliver precision-engineered solutions optimized for extreme environments—from launch vibration to orbital microgravity. Whether for propulsion, life support, or stage separation, Steelhead’s vessels combine lightweight design with proven durability, helping our partners reduce mission risk, improve payload capacity, and achieve operational success.

Challenges

Cost vs. Weight Optimization

Balancing vessel cost with mission-critical weight and risk constraints in aerospace and defense applications

Lightweight Design Integrity

Achieving maximum weight reduction without compromising structural integrity or safety margins

Extreme Environment Containment

Ensuring safe, long-term containment of high-pressure gases in extreme environments, including launch and orbital conditions

Aerospace Certification Compliance

Meeting rigorous aerospace certifications such as AS9100, DOT, and ISO standards for flight and ground systems

Payload Integration Requirements

Adhering to rideshare and payload integration requirements for commercial and government space missions

Solutions and Recommendations

Advanced Pressure Vessel Solutions for Aerospace & Defense
  • Steelhead Engineered Small Pressure Vessels specifically designed for UAVs, satellites, and aerospace systems—offering exceptional strength-to-weight ratios and compact form factors for mission-critical reliability
  • Steelhead High-capacity Large Pressure Vessels tailored for propulsion systems, tank farms, and mobile ground support—enabling scalable, high-pressure energy storage for launch vehicles and space platforms
  • Application-specific Composite Overwrapping that optimizes fiber architecture and resin systems to maximize durability while minimizing weight—customized to meet your exact design and performance specifications
  • Custom port and neck mounting machining services that deliver aerospace-grade components and fittings—ensuring seamless integration with propulsion, life support, and structural systems
  • Steelhead Accelerated Prototype Testing Services including hydrostatic, burst, and , fatigue, environmental testing—validating performance and fast-tracking compliance with aerospace and defense standards

Relevant Projects

Launch vehicle propulsion systems

Steelhead’s high-performance composite overwrapped pressure vessels (COPVs) are integrated into launch vehicle propulsion systems where weight, reliability, and pressure containment are mission-critical. These vessels are engineered to withstand extreme acceleration, vibration, and thermal cycling, ensuring consistent fuel or oxidizer delivery during ascent. Their lightweight construction contributes to improved payload capacity and fuel efficiency—key metrics in commercial and government launch programs.

Spacecraft propulsion tanks

For orbital and deep-space missions, Steelhead provides custom-designed COPVs that serve as primary or auxiliary tanks for spacecraft propulsion systems. These vessels are built to operate in vacuum and microgravity environments, with materials and liners selected for compatibility with hypergolic, cryogenic, or pressurized gas propellants. Their proven performance in long-duration missions supports satellite station-keeping, orbital maneuvering, and interplanetary propulsion.

Flight-critical breathing oxygen

Steelhead’s small-format pressure vessels are used in life-support systems for both crewed spacecraft and high-altitude aircraft. These tanks are certified for oxygen service and designed to meet stringent aerospace safety standards. Their compact, lightweight form factor makes them ideal for integration into ejection seats, pilot breathing systems, and emergency oxygen supplies—where reliability under pressure is non-negotiable.

Lightweight one time use pressure vessels

In applications such as stage separation, pyrotechnic actuation, or emergency system deployment, Steelhead supplies single-use COPVs that are optimized for weight and performance. These vessels are engineered for precise burst or discharge characteristics and are often used in expendable systems where every gram counts. Their design balances cost-efficiency with aerospace-grade quality, making them ideal for mission-specific use cases.