The Pilot Group

What The Pilot Group does

Re:Build Manufacturing is a U.S.-headquartered integrated design, engineering, and contract manufacturing company operating across five industry verticals: Aerospace & Defense, Electrification, Energy & Environment, Medical, and Robotics & Automation. Founded in 2020 and based at 161 Worcester Road, Framingham, Massachusetts, the company reports a network of 14+ U.S. sites, approximately 1 million square feet of industrial space, 1,100+ employees, and 400+ engineers. It runs a coordinated multi-company model: Re:Build Manufacturing, LLC as the parent, Re:Build Manufacturing Solutions, LLC as the centralized program management and procurement entity, plus operating member companies including Re:Build Battery Solutions and Re:Build DAPR (home of The Test Kitchen battery prototype lab).

The technology stack rests on proprietary methodologies and platforms. Manufacturing Constrained Design™ (MCD) and Brain to Box™ are design-to-production methodologies; smartBuild is a digital wire harness assembly platform with cloud-connected software, adaptive operator instructions, and real-time continuity verification; Versaweld™ is a patented portable sterile tube welder using hot-ribbon technology; Stack Health Monitor is a custom embedded grid-scale battery monitoring system with self-calibration and fault detection; and a Modular BMS Platform supports active cell balancing and predictive maintenance logging. Additional capabilities include machine vision quality inspection, automated battery pack assembly cells designed for 150,000+ packs annually, and a UAV (XRAE-1) development program that progressed from concept to flight test in four months.

The business model is direct B2B enterprise engagement with project-based custom pricing (no publicly disclosed rates). Revenue streams span engineering services (product design, prototyping, mechanical/electrical engineering), contract manufacturing (full-rate production across verticals), and managed services through Re:Build Manufacturing Solutions. Customer segments split between startups requiring incubation and established enterprises seeking capacity or new product introduction; AS9100 Rev D certification and ITAR-compliant processes position the firm for defense and aerospace primes. The ownership commentary notes a privately held, zero-debt structure with an engaged long-term investor base.

Name

The Pilot Group

Legal name

Re:Build Manufacturing, LLC

Website

https://the-pilot-group.com

Company type

Private

Founded year

2020

Operating status

Operating

Headcount range

11–50 employees

Short description

Re:Build Manufacturing is an integrated U.S. design, engineering, and contract manufacturer serving aerospace, defense, electrification, energy, medical, and robotics customers across 14+ sites with 1,100+ employees and proprietary platforms including smartBuild and Versaweld.

Ownership category

akta.pro rank

Product category

Engineering and Manufacturing Services

NAICS

Aircraft Manufacturing (336411), Aerospace Product and Parts Manufacturing (33641), Other Aircraft Parts and Auxiliary Equipment Manufacturing (336413)

SIC

Aircraft (3721), Aircraft Parts & Auxiliary Equipment, Nec (3728)

akta.pro primary industry

Military Fixed-Wing Aircraft Manufacturing (IMABAAAB)

akta.pro secondary industry

Military Avionics, Mission Computers & Flight Controls (IMABAMAE)

Keywords

• Machine design services
• Control systems engineering
• Electronics design fabrication
• Industrial manufacturing services
• Prototype to production

Headquarters

HQ city

Framingham

HQ country

United States

HQ region

North America

Offices4 records

Markets served

GTM type

B2B

Offering type

Services

Cost components

Personnel, Operations, Technology or R&D, Infrastructure, Marketing or Sales, Supply Chain

Revenue model

1. Engineering Services: Integrated engineering services spanning product innovation, user-centered design, industrial design, mechanical engineering, electrical systems integration, prototype development and testing, and manufacturing execution.
2. Contract Manufacturing: Full-rate production manufacturing services for aerospace, defense, electrification, energy, medical, and robotics applications. Includes advanced fabrication, modular construction, and assembly line development.
3. Manufacturing Solutions Administration: Centralized sales, supply chain management, customer service, and invoicing for multi-company project delivery through Re:Build Manufacturing Solutions entity.

Go-to-market motion1 record

Distribution channels1 record

Marketing channels4 records

Core offering

The Pilot Group provides machine, control systems, and electronics design and fabrication services. The company supports clients from concept through full-rate production with integrated design, engineering, prototyping, and scalable manufacturing capabilities. Services span aerospace, defense, electrification, energy, medical, and robotics sectors, with proprietary methodologies such as Manufacturing Constrained Design ensuring products are optimized for production from inception.

Product overview

Re:Build Manufacturing is a multi-disciplinary innovation company offering integrated design, engineering, and scalable manufacturing services across five industry verticals: Aerospace & Defense, Electrification, Energy & Environment, Medical, and Robotics & Automation. The company's service portfolio includes both project-based engineering services and proprietary products. Key proprietary offerings include: smartBuild (digital wire harness assembly platform), Versaweld™ (portable tube welder), Stack Health Monitor (battery monitoring), and Modular BMS Platform (battery management systems). The company also delivers specialized manufacturing solutions for EVs, UAVs, thermal energy storage, medical diagnostics automation, and battery production. Re:Build operates under a Manufacturing Constrained Design™ (MCD) methodology ensuring products are designed for scalable production from inception. The ecosystem includes member companies like Re:Build Battery Solutions and The Test Kitchen prototype facility.

Differentiator

Problem solved

Functional benefit

Brands

• Re:Build Battery Solutions: Custom battery design, BMS, and scalable production services for aerospace, defense, and energy storage applications
• The Test Kitchen
• Re:Build Manufacturing Solutions (RBS)
• smartBuild
• Versaweld

Products and services

• smartBuild Digital Assembly Platform A digital wire harness assembly platform that replaces traditional analog formboards with an integrated system combining purpose-built hardware, cloud-connected software, and real-time quality verification. Guides operators through assembly, verifies quality in real-time, and adapts to design changes. Targets wire harness manufacturers with reported 18-20% build time reduction and 95% reduction in design-to-build time.
• Versaweld Portable Tube Welding System A portable, battery-powered sterile tube welding system for pharmaceutical and biologics manufacturing, featuring patented hot ribbon technology for combined cutting and welding, multi-use ribbon cassette system, and universal tube size capability. Designed for life science and bioprocessing applications.
• Stack Health Monitor (SHM) Custom embedded monitoring solution for grid-scale flow battery systems that tracks cell voltages, detects faults, and ensures safe operation across hundreds of cells. Achieves 90% unit manufacturing cost reduction compared to commercial alternatives while improving measurement stability over 20-year operational lifespan. Features real-time data acquisition, automatic continuous self-calibration, and fault detection.
• Modular BMS Platform Custom battery management system designed for lightweight electric motorcycles with cell protection, performance monitoring, system diagnostics, ITAR compliance, active cell balancing, state-of-charge tracking, and embedded data logging for predictive maintenance.
• XRAE-1 Foundation UAV A large flying-wing UAV technology demonstrator developed in four months from concept to flight test, featuring proprietary design optimization software, composite airframe, and integrated propulsion systems achieving 2-3+ hour flight endurance, 75 mph max speed, and 16-foot wingspan. Targets aerospace and defense applications.
• Slate Electric Vehicle Platform Integrated development program for a simplified electric vehicle platform priced below $25,000, covering battery pack design, BMS, electrical architecture, wire harness design, automation, and advanced composite structural components.
• Thermal Energy Storage System High-temperature thermal energy storage system designed to store megawatt-hours of thermal energy at temperatures approaching 2000°C for renewable energy applications.
• Battery Pack Assembly Robotic Cell Automated battery pack assembly system featuring robotic cell design, custom end-of-arm tooling, AGV integration, and proof-of-concept validation for high-volume EV battery production exceeding 150,000 packs annually.
• Automated PCR Reagent Table Automated reagent preparation workcell for high-throughput diagnostic testing, featuring precision mechanical engineering, thermal management, robotics integration, machine vision quality control, and modular equipment design. Precision positioning within ±30 microns for RT-PCR plate processing.
• Self-Deployable EV Solar Array Self-deployable solar charging array system for electric vehicle charging applications, developed from concept to deployable prototypes for international pilot testing.
• Factory & Process Build Services Turnkey emergency facility reconstruction services including multi-disciplinary engineering, hazardous area design, custom process equipment, structural/civil engineering, modular construction, control panel design, automation integration, and supply chain management. Includes facility reconstruction completed within six-month timeframe for chemical manufacturing clients.
• Re:Build Battery Solutions (Member Company) A dedicated member company providing custom battery design, BMS development, and scalable battery production services for aerospace, defense, and energy storage applications from a 175,000 sq ft ITAR-compliant facility expandable to 750,000 sq ft.
• The Test Kitchen Battery Prototype Lab A 2,000 sq ft battery pack prototype assembly lab in Nashua, NH for high-mix lithium-ion battery pack prototyping and process development. Supports assembly and testing of Li-ion battery packs up to several kWh, processing 18650 and 21700 cylindrical cells with capacity of 15 MWh/yr.
• Integrated Design, Engineering, and Manufacturing Services Core service offering providing integrated design, engineering, prototyping, and scalable manufacturing capabilities for machine, control systems, and electronics products across aerospace, defense, electrification, energy, medical, and robotics sectors. Includes product innovation, user-centered design, industrial design, mechanical engineering, electrical systems integration, prototype development, testing, and manufacturing execution.

Quantifiable outcome

• 18-20% reduction in wire harness build time per harness
• +6 more outcomes

Named customers9 records

Segments7 records

Ideal customer profiles5 records

Technology focussed No

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

AI capability10 records

Feature5 records

Partnerships

Two partnerships are on record, tiered notable.

• SlatenotableStrategic or Co-development Partner · 1 January 2023Slate was initially incubated within Re:Build's ecosystem as an electric vehicle startup concept. Re:Build provided integrated strategy, design, and engineering capabilities to help define the product strategy. After becoming independent, Slate partnered with Re:Build for battery pack design, BMS electronics, wire harness design, and manufacturing development for their sub-$25,000 EV platform. The relationship evolved from internal incubation to external strategic partnership.
• EnsorcellnotableStrategic or Co-development PartnerEnsorcell emerged as a life science tools business out of Re:Build Manufacturing. The collaboration delivered the Versaweld portable tube welding system through integrated engineering innovation, user-centered design, brand development, and manufacturing expertise. Re:Build applied Manufacturing Constrained Design™ principles to create a market-ready product.

Scale indicators12 records

Recent moves9 records

Expansion highlights6 records

Broad incumbents

• Jabil: Large diversified electronics manufacturing services provider serving aerospace, defense, automotive, and healthcare. Comparable to Re:Build in contract manufacturing business model and multi-vertical strategy, though Jabil operates at significantly greater scale and global reach.
• Flex Ltd: Global contract manufacturer with multi-billion dollar revenue serving aerospace, automotive, and industrial customers. Comparable to Re:Build as a scaled EMS/contract manufacturing peer, though Flex is far larger and more diversified globally while Re:Build focuses on U.S. advanced manufacturing.
• Mercury Systems: U.S. defense electronics manufacturer serving aerospace, defense, and intelligence markets with mission-critical subsystems. Comparable to Re:Build's defense electronics work including BMS and Stack Health Monitor for aerospace applications, though Mercury is far larger and product-focused.
• Rocket Lab: U.S. aerospace manufacturer and launch services provider with vertically-integrated space systems. Comparable to Re:Build in aerospace manufacturing capabilities and defense/aerospace customer base, though Rocket Lab is far larger, space-focused, and product-driven.
• Kratos Defense & Security Solutions: U.S. defense manufacturer producing unmanned systems, jet engines, and microwave electronics. Comparable to Re:Build in defense/UAV manufacturing and U.S.-based advanced manufacturing focus, though Kratos is far larger and specializes in tactical drones and propulsion.

Direct peers

• Benchmark Electronics: Contract manufacturer specializing in aerospace, defense, medical, and complex industrial markets with U.S.-based engineering and manufacturing. Highly comparable to Re:Build in customer segments (A&D, medical), complexity of builds, and emphasis on engineering-intensive programs.
• Sanmina: U.S.-headquartered contract manufacturer with strong aerospace/defense, medical, and industrial verticals. Closely comparable to Re:Build in target markets (aerospace/defense, medical, industrial), business model (integrated manufacturing), and customer profile. Both serve AS9100-certified programs.
• AeroVironment: U.S. defense and aerospace company developing unmanned aircraft systems including fixed-wing UAVs. Directly comparable to Re:Build's XRAE-1 UAV work and broader defense UAV/drone manufacturing capabilities, though AeroVironment is far larger and product-focused versus Re:Build's service model.

Emerging players

• CelLink: U.S.-based manufacturer of flexible wire harnesses and power cabling for EV and clean energy customers. Comparable to Re:Build's smartBuild digital wire harness platform and electrification focus, though CelLink is more narrowly focused on high-volume wire harness production.
• Hadrian: U.S.-based advanced contract manufacturer using automation and software to produce precision components for aerospace and defense. Comparable to Re:Build as a modern, U.S.-focused contract manufacturer serving defense primes with technology-enabled manufacturing, though Hadrian focuses on CNC machining components rather than integrated systems.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat6 records

Key risks6 records

Key highlights7 records

Customer concentration

• LinkedInlinkedin.com/company/re-build-manufacturing

Compliance2 records

Revenue estimate

Valuation estimate

Number of profiles

Profiles1 record

Subsidiaries3 records

Funding overview

Funding rounds

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about The Pilot Group