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“No aircraft manufacturer is doing what we are doing in house.”

ICON Aircraft has been developing the A5 light sport amphibious airplane for the better part of the past decade. And for the first time, we’re offering an in-depth, behind-the-scenes look at where the A5 begins.

ICON has gone through great strides to develop the ability to develop a carbon fiber aircraft in our own facilities. More than two years ago, we made the decision to build our own composite manufacturing facility so that we could control the detailed process of bonding the carbon fiber fuselage of the ICON A5 from beginning to end.

The composite manufacturing process begins at our facility in Tijuana, Mexico. This facility is over 300,000 square feet and is responsible for manufacturing more than XX carbon fiber parts for each ICON A5. The A5’s fuselage is entirely carbon fiber, which provides great structural integrity at a considerably lighter weight than comparable materials.

We can’t show you exactly how the A5 is made (some of our technology and processes are proprietary), but this video offers great insight into what it takes to produce a carbon fiber-based light sport airplane.