Scion Aviation Utilizes State-of-The-Art Tooling Board to Maintain Tight Tolerances on Carbon Fiber Components for Autonomous Helicopter.
New BLACK CORINTHO® 800 high-temp polyurethane tooling board used to realize low co-efficient of thermal expansion on tooling project

Scion Aviation (Fort Collins, CO) has completed prototype tooling for the external fuel pods for their upcoming SA-410 and SA-415 Vixen manned/optionally manned helicopter system, using a new state-of-the-art tooling board from DUNA-USA, the BLACK CORINTHO® 800.

In preparation for upcoming flight tests, Scion needed to create external carbon fuel tanks for the Vixen helicopter line, and maintaining accuracy was key. The BLACK CORINTHO® 800 was utilized in a direct-tool application, and once the boards were bonded, CNC machined, and sealed, Hexcel M35-4 epoxy prepreg was layed up onto the tool, and cured in an autoclave for 16 hours at 50 PSI/180°F. 

DUNA-USA will be showcasing the tool and respective parts at the upcoming CAMX exhibition, October 16-18 in Dallas, TX at booth # Q48.

“For years, making low-cost, highly accurate prototypes with the available tooling options was next to impossible. Metal tooling is heavy, expensive, and overkill 9 times out of 10 for this type of application. The natural solution is tooling board, but traditionally, the co-efficient of thermal expansion has proven to be prohibitive to maintaining the necessary tolerance for a highly-accurate prototype,” says Jim Sampson, owner of Scion Aviation. 

“For Scion, the BLACK CORINTHO® fits the sweet spot in this regard in that it is highly stable, has an ultra-low coefficient of thermal expansion, and significantly sped up our process allowing relevant savings in time and money. It has truly changed our working method and enabled us to be more competitive in our quoting process.”

The Vixen helicopter line consists of unmanned/optionally manned variations, and is currently undergoing flight testing by Scion Aviation in collaboration with Safran for ultimate use as offshore patrol vessels (OPV) and other applications for the US Navy, US Army and civilian use-cases. The program has been in development since 2011, and full-scale production is slated for 2019 and will be conducted by Scion Aviation’s Fort Collins, CO and Cheyenne, WY locations. 

The BLACK CORINTHO® 800 is a high-temperature tooling board, designed for use up to 400F, offering low CTE, high dimensional stability, and high thermal conductivity. It is designed to produce prototype, or low-volume tooling, and is part of a high-temperature tooling system developed by the DUNA Group consisting of the BLACK CORINTHO® series tooling boards, DUNAPOX™ BLACK AD 135 high-temp epoxy adhesive and the DUNAPOX™ BLACK SEA 125 high-temp epoxy sealer. 

Scion Aviation was founded in 1994 by Jim Sampson after his graduation from Embry-Riddle Aeronautical University, and specializes in manned/unmanned aviation development and prototype tooling using the latest in machinery and state-of-the-art technology. They have locations in Fort Collins, CO and Cheyenne, WY, and are AS9100 certified and fully ITAR compliant. 

Additional information may be seen at:

The DUNA Group, comprised of DUNA-USA, DUNA-CORRADINI, and DUNA-EMIRATES, has been manufacturing foams, chemicals, and adhesives for the insulation, modeling, signage, tooling, aerospace and composites industries since 1957. They have locations in the USA, Italy, and United Arab Emirates. 

Additional information can be seen at:

Here at Scion Aviation, we value our interns and enjoy showing them the many intricacies that is the aerospace business. From design to the layup process, to final details, our interns learn what it takes to deliver exceptional quality products. We had the pleasure of mentoring Addison, Anders and Chandon this summer, and we wish them a continued passion for flight and a successful career in the aerospace business! 


34th Space Symposium, April 16-19th

The Space Symposium, held at The Broadmoor in Colorado Springs, Colorado, USA, has brought together space leaders from around the world to discuss, address and plan for the future of space since the inaugural event in 1984. Attendees at that original event numbered barely 250 space enthusiasts, while participants in recent years have surpassed 11,000. The Space Symposium has become widely known as the premier U.S. space policy and program forum and as the "must attend" opportunity for information on and interaction among all sectors of space.


If you’re looking to harness the power of unmanned technology, AUVSI XPONENTIAL 2018 is the spot. An intersection of cutting-edge innovation and real-world applications, XPONENTIAL is the one event that brings all things unmanned into sharp focus. Join more than 8,500 industry leaders and forward-thinking users from both the defense and commercial sectors to learn the latest on policy, business use cases and technology applications—and grab your share of this billion dollar industry.

SAMPE North America May 21-24, 2018

The Society for the Advancement of Material and Process Engineering (SAMPE®) is a global professional member society that provides enhanced educational opportunities, by delivering information on new and advanced materials and processing technology. SAMPE provides growth and educational opportunities via conferences, exhibitions, technical forums, and publications. As the only technical society encompassing all fields of endeavor in materials and processes, SAMPE provides a unique and valuable forum for scientists, engineers, and academicians. SAMPE North America is a regional subsidiary of SAMPE that serves Canada, Mexico, and the United States.

Scion Aviation LLC signs multi- year composite airframe supply agreement with PAE ISR LLC.

Scion Aviation, a leading manufacturer of composites for aerospace, announces a multi- year supply agreement for the Resolute Eagle.

PAE ISR and Scion have worked together to advance the design and build of the Resolute Eagle fleet. Scion will provide all composite parts, sub-assemblies and tooling for PAE ISR’s full carbon fiber UAV. Both companies have worked closely to rapidly develop, produce and support this innovative UAV program. Scion has assisted PAE ISR over the last few years with design, prototype and tooling producing a fleet for PAE ISR to test.

Scion will supply PAE ISR from facilities in both Colorado and Wyoming in the United States.

Jim Sampson, founding CEO of Scion Aviation states, “We are very happy to be part of PAE ISR’s next generation multi-purpose lightweight UAV. Through this multi-year agreement, we reinforce our partnership with PAE ISR in supporting them with ramp up and production of the Resolute Eagle.”

“PAE ISR is honored to be awarded a position on the $1.7B Navy CRUAS ISR IDIQ that will provide world-wide ISR services in support of the U.S military,” said Jake Jacobs, Chief Technology Officer of PAE ISR. “This victory for PAE ISR is directly attributable to the outstanding team assembled, including SCION Aviation and their state-of-the-art development and production capability. We rely on SCION Aviation to produce high quality products, on time and on budget, and we look forward to future partnership opportunities.”

 About Scion Aviation:

 Scion Aviation LLC is a leader in the development and production of advanced structural composites. Its product portfolio includes aerospace, space, experimental and certified products and tooling. Scion Aviation has production facilities in Colorado and Wyoming. As a full-service composites provider, Scion offers high-quality manufacturing, quality assurance and engineering services. The company has proactively expanded its manufacturing capacities by adding a new manufacturing plant in Cheyenne, Wyoming.



OSHKOSH 7/25-7/31 2017

Action, education, entertainment, and everything in between makes EAA AirVenture Oshkosh your perfect, affordable summer destination!

For seven days from sunrise to well past sunset, your Oshkosh day is filled dazzling displays of aerobatics, informative programs and hands-on workshops, diverse aircraft spanning all eras of flight, concerts to keep you rockin’ into the night, and much, much more.

Fun for the whole family that you’ll find only in Oshkosh is waiting for you at The World’s Greatest Aviation Celebration!