Royal Engineered Composites announces $5M expansion

Royal Engineered Composites, a leading manufacturer of advanced composite structures, today announced a 23,500-square-foot expansion of its Minden, Nebraska facility. The $3M building addition, coupled with $2M in new equipment, positions Royal to provide full-scale, in-house manufacturing for large section-level assemblies.

The expansion optimizes the workflow for large-scale parts, creating a seamless environment for Royal to cure, trim & inspect large parts in-house. Central to this investment is the acquisition of a large-format SDI Delta X Gantry C-Scan system, scheduled for delivery in July 2026.

"Over the past few years, we’ve added larger assemblies that pushed the boundaries of our existing footprint," said Dave Arnold, President of Royal Engineered Composites. "This expansion isn't just about more space; it's about providing a complete, in-house solution. By eliminating the need to ship large parts to third parties for inspection, we significantly reduce lead times and maintain the flexibility our customers require."

Added Capabilities

The investment includes a suite of new technology designed for precision and speed:

- SDI Delta X Gantry C-Scan: A 10-axis, dual-head overhead system (180" x 72" x 120") featuring dual-frequency detection (1Mhz and 5Mhz). It includes - a Tone Burst/Square Wave Pulser specifically for penetrating highly attenuative materials.

- CMS Model 3618 CNC: High-capacity machining with dual-zone trimming capability, now fully operational.

- Rapid Prototype Post-Cure Oven: Significantly compresses lead times for new programs by accelerating tool development.

- Mobile FARO Inspection: Provides dynamic, high-precision measurement for large-format parts anywhere on the floor.

Workforce Growth

The facility expansion coincides with a significant hiring initiative. Royal is in the process of adding 70 new positions, 46 of which have already been filled, bringing the total workforce to approximately 250 employee-owners.

Groundbreaking Event

A formal groundbreaking ceremony will take place at the Minden facility on April 20th. Members of the press, industry partners, and the public are invited to attend. The building expansion is expected to be complete by the end of 2026.