MASK Control Systems - Bespoke Industrial Automation & Control Systems UK
Aerospace & Defence Engineering • Precision, Security & Full Traceability

Aerospace & Defence
Automation Solutions

MASK Control Systems designs and delivers automation solutions for aerospace and defence manufacturers across the UK and worldwide. Since 2013, we have engineered PLC control systems, control panels, and fully integrated automation solutions for safety-critical environments where precision and documentation matter as much as performance.

Our team understands the standards, the security requirements, and the zero-tolerance approach to defects that define this sector, and we build every project around them.

Zero
Defect Tolerance
SIL 2/3
Safety & PL e
Full ECO
Code Traceability
3 Continents
Global Deployment
Aerospace & Defence Automation Solutions - MASK Control Systems Ltd
SYSTEM ARCHITECTURE:FAIL-SAFE PLC / SCADA
STANDARDS ALIGNMENT:AS9100 • DEFCON • ISO 9001
REVISION DISCIPLINE:FORMAL ECO TRACEABILITY
UK ENGINEERING: CULLOMPTON, DEVONEST. 2013
Trusted by Aerospace & Defence Contractors:
UK Ministry of Defence partner with MASK Control Systems
Babcock International partner with MASK Control Systems
Field International partner with MASK Control Systems
Dunlop Aircraft Tyres partner with MASK Control Systems
Emirates partner with MASK Control Systems
Alstom partner with MASK Control Systems
Zero-Tolerance Operational Realities

Why Aerospace & Defence Manufacturing Needs Specialized Automation

Aerospace and defence manufacturing operates under a level of scrutiny that few other sectors match. Systems must perform within extremely tight tolerances, and a single defect can carry consequences far beyond a production line.

Tight Tolerances & Zero Defect Consequence

In aerospace and defence, a single logic error or dimensional deviation can compromise human life or trigger massive mission failure. Systems must execute with deterministic precision every single cycle.

Exhaustive Qualification & Audit Cycles

Qualification and audit cycles run longer and deeper than in commercial sectors. Automation partners must deliver flawless FAT/SAT documentation that withstands intense prime contractor and MoD scrutiny.

Rigorous Configuration & Revision Control

Every system change requires formal configuration and revision control. A complete, unalterable historical log must exist for every component, wiring change, and software update throughout the equipment lifecycle.

Discretion & Strict Information Security

Many aerospace and defence projects involve classified or sensitive IP. Manufacturers require an engineering partner who treats confidentiality as foundational—from data encryption to vetted on-site personnel.

The UK Aerospace & Defence Manufacturing Landscape - MASK Control Systems
UK DEFENCE & AVIATION HUB:SOUTH WEST & MIDLANDS

Supporting prime aerospace contractors, Tier-1 system suppliers, and defence programs across the UK with security-conscious, accredited engineering.

National Engineering Ecosystem

The UK Aerospace & Defence
Manufacturing Landscape

The UK aerospace and defence sector is one of the country's most established advanced manufacturing bases, supporting thousands of companies and tens of thousands of skilled engineers across design, production, and systems integration.

The South West of England, where MASK is headquartered in Cullompton, Devon, is a particularly dense engineering region for this sector—home to a large concentration of aerospace engineers and a long-standing supply chain built around major defence and aviation programs.

The Security-Cleared Engineering Skills Shortage

This sector faces a pronounced skills challenge. Security-cleared automation engineers are in short supply nationally, and many manufacturers find it difficult to recruit and retain the specialized talent needed to maintain and upgrade safety-critical control systems. That shortage is pushing more manufacturers toward experienced outsourced partners like MASK Control Systems who step in with the right documentation discipline and technical depth already in place.

Operational Assessment & Review

Signs Your Aerospace or Defence Facility Needs Automation Support

Several recurring signals tell us an aerospace or defence facility is ready for an automation review before risks escalate into costly audit failures or line stoppages:

01

Aging End-of-Life PLC Systems

Legacy control systems are approaching end-of-life with no clear upgrade path or manufacturer spare parts availability.

Risk Mitigation Priority
02

Traceability & Audit Bottlenecks

Manual documentation and paper-based configuration logs struggle to keep pace with stringent defense traceability and audit demands.

Risk Mitigation Priority
03

Internal Engineering Capacity Deficits

In-house engineering teams lack the available hours or specific security clearances required to undertake new safety-critical automation programs.

Risk Mitigation Priority
04

Compliance Audit Documentation Gaps

Recent quality audits have flagged gaps or inconsistencies in control software change history, schematics, or component traceability.

Risk Mitigation Priority
05

Disproportionate Safety-Line Downtime

Unscheduled downtime on safety-critical assembly or testing lines creates unacceptable commercial penalties and operational risk exposure.

Risk Mitigation Priority
06

Obsolete Control Panel Components

Existing control cabinets rely on obsolete relays, discontinued drives, or unsupportable safety circuits with no direct vendor replacements.

Risk Mitigation Priority

Recognize any of these challenges in your facility?

An automation and control system review is worth prioritizing before audit or obsolescence issues escalate.

Schedule an Engineering Audit
Comprehensive Technical Capabilities

Our Aerospace & Defence
Automation Services

From safety-critical PLC logic to bespoke control cabinets and legacy modernization, we engineer end-to-end automation systems built around rigorous documentation, functional safety, and complete accountability.

PLC Programming & Control Systems - MASK Control Systems Ltd
CAPABILITY 01
Safety-Critical Logic & Full Revision Traceability

PLC Programming & Control Systems

We develop robust control logic for safety critical aerospace and defence applications using industry standard platforms like Siemens, Mitsubishi, and Unitronics. Our programming approach emphasizes strict documentation and full traceability from the initial line of code to the final deployment. This ensures that every operation is completely auditable to meet rigorous industry compliance standards. We deliver solutions that prioritize both precise execution and comprehensive historical logging for your peace of mind.

Siemens S7-1500F Fail-Safe, Mitsubishi MELSEC-Q/iQ-R, Unitronics UniStream
Deterministic, fail-safe logic architecture aligned with IEC 61508 / 62061
Complete software version control, code commenting, and revision logs
Comprehensive historical fault logging and audit-ready data trails
Electrical Control Panel Design & Build - MASK Control Systems Ltd
CAPABILITY 02
Precision Engineering with Complete Component Pedigree

Electrical Control Panel Design & Build

We specialize in engineering and manufacturing control panels that adhere to the stringent documentation and build quality expectations of the aerospace and defence sector. Every panel we build includes a complete, detailed record of all internal components, their sourcing, and the results of our rigorous testing process. This commitment to transparency ensures that your systems are reliable and easy to maintain throughout their entire lifecycle. We focus on structural integrity and precision to provide a foundation that supports your most critical manufacturing tasks.

Full component provenance and traceable bill of materials (BOM)
EMC shielded, vibration-resistant, and high-integrity enclosures
Detailed CAD electrical schematics, wire tagging, and terminal maps
Rigorous 100% point-to-point Factory Acceptance Testing (FAT)
Functional Safety Engineering - MASK Control Systems Ltd
CAPABILITY 03
SIL 2/3 & PL e Architectures for High-Consequence Operations

Functional Safety Engineering

Our team performs detailed risk assessments and designs safety systems specifically for high consequence environments where precision and reliability are non negotiable. We ensure that every safety critical function is meticulously engineered, thoroughly tested, and extensively documented to meet the demanding standards of the aerospace industry. By prioritizing safety at the architectural level, we help you mitigate operational risks and protect your personnel and assets. Our documentation provides the evidence required for successful internal reviews and external audits.

Comprehensive EN ISO 13849-1 (PL e) and IEC 62061 (SIL 3) design
Safety PLC programming and redundant fail-safe interlock networks
Formal Hazard Identification (HAZID) and risk assessments
Exhaustive safety validation reports for defence audit sign-off
Systems Integration - MASK Control Systems Ltd
CAPABILITY 04
Cohesive Multi-Platform Coordination & Test Rig Control

Systems Integration

We manage the complex coordination of multi system environments where diverse equipment, control platforms, and safety systems must function as a single unit. This integration phase is often the most demanding part of an aerospace project, requiring deep technical expertise to ensure complete reliability across your infrastructure. Our end to end delivery model simplifies this process by keeping all coordination under a single accountable engineering partner. We unify your disparate production technologies to create a cohesive and highly efficient manufacturing process.

Unification of legacy machinery, modern robotic cells, and test rigs
Fieldbus networking via PROFINET, PROFIsafe, CC-Link IE, and Modbus TCP
Interfacing with aerospace manufacturing execution systems (MES)
Single accountable engineering partner eliminating contractor friction
HMI & SCADA Development - MASK Control Systems Ltd
CAPABILITY 05
Auditable Operator Interfaces & Secure Telemetry

HMI & SCADA Development

We create secure, auditable operator interfaces and SCADA dashboards that provide your team with clear visibility into real time production performance. Our development process prioritizes user accessibility while maintaining the strict security protocols and access logging required in sensitive defence environments. We deliver intuitive control systems that simplify complex data without compromising the security or auditability of your operations. This empowers your operators to maintain high standards of efficiency and control throughout every production cycle.

Role-based multi-tier security and biometric/RFID user authentication
Tamper-proof electronic records and historical change audit logging
Intuitive visual alarm diagnostics minimizing operational confusion
Air-gapped and secured industrial network telemetry options
Installation & Commissioning - MASK Control Systems Ltd
CAPABILITY 06
Structured On-Site Deployment with Documented SAT

Installation & Commissioning

We oversee the entire on site installation and commissioning phase, maintaining a precise documentation trail at every step of the deployment. This structured approach ensures that your project is ready for immediate internal sign off and provides all the necessary evidence for external audits upon completion. Our team manages the logistical challenges of integration, allowing you to focus on your core production goals. We remain on site to verify that everything performs to specifications, ensuring a smooth transition to full operation.

Structured Site Acceptance Testing (SAT) with redlined as-built packages
Security-conscious deployment adhering to facility access protocols
Minimal production disturbance and coordinated cutover windows
Comprehensive operator and maintenance personnel handover training
Legacy System Upgrades - MASK Control Systems Ltd
CAPABILITY 07
Modernizing End-of-Life Control Systems Without Production Interruption

Legacy System Upgrades

We provide professional modernization services for outdated PLC and control hardware that has reached or is nearing its end of life. Our strategy focuses on upgrading your systems to current standards while minimizing any disruptions to your ongoing production schedule. By systematically addressing obsolescence risks, we extend the operational lifespan of your critical manufacturing lines. We ensure a seamless transition that restores reliability to your older infrastructure without compromising the performance of your current facility.

Risk-mitigated migration from legacy Siemens S5, Mitsubishi A/Q, or SLC500
Drop-in I/O conversion and parallel wiring strategies for rapid cutover
Complete obsolescence management and long-term spares availability
Preservation of proven operating kinematics and manufacturing parameters
Flight-Line & MRO Automation

Specialized Ground Support (GSE) & Aircraft Tooling Automation

In addition to fixed manufacturing lines, MASK engineers high-reliability control systems and sensor telemetry for mobile airfield equipment and aircraft maintenance tooling (AMT).

Ground Support Equipment (GSE) Automation - MASK Control Systems Ltd
Towbarless Tugs, Mobile Power & Hydraulic Rigs

Ground Support Equipment (GSE) Automation

We engineer ruggedized, failsafe control systems for aviation ground handling and mobile flight-line equipment. Built to withstand extreme environmental conditions, heavy vibration, and continuous airfield duty cycles while providing precise load monitoring and operator interlocks.

CANbus J1939IP67 In-Cab DisplaysHydraulic Manifold ControlSafety Interlocks
Aircraft Maintenance Tooling (AMT) - MASK Control Systems Ltd
Calibrated Lifting Beams, Engine Cradles & Test Rigs

Aircraft Maintenance Tooling (AMT)

Custom automated control systems and telemetry for aircraft maintenance tooling, engine overhaul stands, and structural proof-load testing rigs. Complete with certified load cell calibration, digital displacement recording, and automated test certification reporting.

Synchronized LiftingLoad Cell TelemetryISO 17025 CalibrationAudit Reporting
Standards & Quality Management

Compliance, Traceability
& Security Built In

Aerospace and defence manufacturing runs on documented, auditable processes, and our systems are built to support that from day one.

We align our work with AS9100 and DEFCON standards, and we apply strict configuration and change management to every system revision, so a complete history exists for every modification made throughout a system's life. Our documentation is built to withstand the level of scrutiny that prime contractors and defence procurement bodies expect during audit.

We also take confidentiality seriously. Where a project involves sensitive or restricted information, we apply appropriate access controls and handling procedures throughout our engineering process, from initial design through to on-site commissioning.

ISO 9001 Certified
ISO 17020 Accredited
ISO 17025 Calibrated

AS9100 & DEFCON Aligned

Our quality management procedures and technical deliverables align directly with aerospace (AS9100) and UK Ministry of Defence procurement expectations.

ISO Accredited Quality

Holding ISO 9001, ISO 17020, and ISO 17025 accreditations, we bring formal quality assurance, calibration rigor, and inspection discipline to every build.

Rigorous Configuration Control

Every logic revision, wiring modification, and component change is captured in formal engineering change orders (ECO) with complete audit histories.

Information Security & Discretion

Strict data handling, NDAs, and physical security measures protect proprietary aviation IP, military specifications, and sensitive program details.

UK Headquarters • Worldwide Deployment

Supporting Aerospace & Defence Manufacturers Worldwide

We are headquartered in Cullompton, Devon, in the United Kingdom, and we apply the same engineering discipline and documentation standards to aerospace and defence projects across three continents.

Whether your facility is based in the UK, mainland Europe, North America, or the Middle East, you receive the same rigorous process, the same certified quality management systems, and the same commitment to long-term lifecycle support.

UK & EUROPE
Devon HQ & Midlands Hub

Rapid on-site emergency engineering, commissioning, and scheduled maintenance across the UK defence corridor and European manufacturing hubs.

NORTH AMERICA & MIDDLE EAST
International Deployment

Full SAT commissioning, turn-key FAT validation, and remote telemetry support for multinational aviation suppliers and defence facilities.

DATA SECURITY
Secure Remote Telemetry

Air-gapped architecture design, encrypted VPN gateways, and role-based remote diagnostics adhering to strict client cyber policies.

Structured Engineering Delivery

How We Work

We follow a structured, documented process on every aerospace and defence project to guarantee total traceability and compliance:

01

Consultation & Audit

We assess your technical specifications, security parameters, compliance obligations, and project feasibility before engineering begins.

STAGE 01
02

System Design

Our engineers develop comprehensive CAD schematics, functional design specifications (FDS), and safety architectures aligned with your standards.

STAGE 02
03

Build & In-House FAT

We manufacture panels and build control logic in-house, completing 100% rigorous Factory Acceptance Testing with complete documentation prior to dispatch.

STAGE 03
04

Commissioning & SAT

We install on-site, integrate with existing plant systems, and execute structured Site Acceptance Testing while maintaining complete audit trails.

STAGE 04
05

Lifecycle Support

We provide ongoing preventative servicing, remote telemetry, and long-term technical support to keep your systems reliable and fully compliant.

STAGE 05
Engineering Excellence

Why Manufacturers Choose MASK for
Aerospace & Defence Automation

We hold ISO 9001, ISO 17020, and ISO 17025 certifications, and we bring that same quality management discipline to every aerospace and defence project. Our team works across Siemens, Mitsubishi, Unitronics, Allen-Bradley, and Omron platforms, so we recommend the right technology for your application rather than defaulting to a single vendor's equipment.

We manage every project end to end, from initial design through build, installation, commissioning, and ongoing support, so you work with one accountable engineering partner rather than coordinating multiple contractors.

As the shortage of security-cleared, sector-experienced automation engineers continues to affect the industry, we act as an experienced outsourced team who already understands the standards, the documentation, and the scrutiny this sector demands.

Tri-Certified Quality Rigor

ISO 9001 (Quality), ISO 17020 (Inspection), and ISO 17025 (Testing/Calibration) standards integrated directly into our panel manufacturing and code testing protocols.

Vendor-Agnostic Objectivity

Deep engineering capability across Siemens SIMATIC S7, Mitsubishi MELSEC, Unitronics, Rockwell Allen-Bradley, and Omron platforms. We select what fits your application best.

Single Accountable Partner

From concept and panel build to on-site commissioning and 24/7 technical breakdown support, we eliminate multi-vendor friction and finger-pointing.

Overcoming Sector Skills Gaps

Ready-to-deploy engineering specialists possessing the necessary technical depth, safety credentials, and sector familiarity required by prime defense contractors.

Engineering Queries Answered

Frequently Asked Questions

Key questions aerospace and defence manufacturers ask when evaluating MASK Control Systems as their automation partner:

What certifications does MASK hold for aerospace and defence work?
We hold ISO 9001, ISO 17020, and ISO 17025 certifications, and we design our systems to align with AS9100 and DEFCON standards throughout every project.
Can you work on classified or security-sensitive projects?
Yes. We apply appropriate access controls and confidentiality procedures throughout our design and delivery process for projects involving sensitive or restricted information. Specific clearance requirements are discussed and confirmed on a per-project basis.
How do you handle configuration and change control on safety-critical systems?
Every system revision is formally documented, so a complete change history exists for the full life of the system. This supports both internal review and external audit requirements.
Do you support legacy PLC systems that are nearing end-of-life?
Yes. We regularly modernize outdated PLC and control hardware, upgrading systems to current standards while minimizing disruption to ongoing production.
Do you deliver aerospace and defence automation projects outside the UK?
Yes. We deliver projects across three continents, applying the same engineering standards and documentation discipline wherever the project is based.
Industry Sectors

Explore Other Industries We Serve

In addition to aerospace and defence, MASK engineers bespoke control and automation systems across diverse high-performance industrial sectors:

Confidential Project Consultation

Get In Touch With Our Aerospace & Defence Engineers

If you are planning an aerospace or defence automation project, or you need to modernize a legacy control system, our team is ready to help. Explore our other industry sectors or contact us directly to discuss your requirements.

Head Office: Cullompton, Devon, UK Midlands Hub: Birmingham, UK Worldwide Deployment Capability
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