Aeronaut Automation: From accidental beginnings to advanced manufacturing

Some of Australia’s most advanced manufacturing businesses don’t start with a grand plan; they start with curiosity (alongside a great business adviser, of course)!

For Aeronaut Automation Founders Geraldine and John Clark, the business began nearly 40 years ago with a boat, a dissatisfaction with poorly made sails, and a self-taught determination to do things better.

John began designing and making sails himself, then designing machines to automate the process. When the technology proved better than anything available overseas, others in the industry took notice. What began as a small sail loft soon evolved into a specialist manufacturing business designing and building automated cutting machines for industries ranging from blinds and awnings to marine, general aviation and aerospace.

A long-term advisory relationship built on trust

From the outset, Aeronaut Sails (now Aeronaut Automation) grew organically, with innovation leading the way. This followed an earlier chapter in their journey, where PKF Sydney had previously been hired as Geraldine and John’s accountants for their film production business. As their focus shifted from film to manufacturing, in 2011, PKF Newcastle continued alongside them, helping ensure the financial foundations evolved in step with the business’s rapidly expanding growth.

As the business grew from a home workshop into a full-scale factory employing more than 20 staff at its peak, led by now PKF Australia Chairman and PKF Newcastle Partner, Steve Meyn, PKF provided consistent, practical advice that went well beyond compliance.

“We had a lot to learn about managing finances and structuring the business properly. PKF helped us understand how to keep cash flowing, how to fund growth and how to avoid pitfalls we weren’t aware of,” Geraldine reflected.

From structuring accounts and asset purchases to funding decisions and long-term planning, our business advisory team acted as a sounding board and strategic adviser during every stage of growth for Aeronaut Automation.

“Steve's always given us really good advice on just the best way to go about it,” Geraldine said. However, at one point, the business explored cheaper accounting options. The result was costly mistakes and a swift return to PKF – a moment that reinforced the value of quality advice.

“We thought maybe we should try somebody else locally, but within 12 months I was ringing up Steve saying, ‘Please take us back.’ It was a real disaster.

“That gave us a very good understanding of what a good accountant looks like compared to a really average one,” Geraldine says. “PKF has saved us much more money than they’ve ever cost us.”

Cash flow, growth and resilience in Australian manufacturing

As Aeronaut Automation expanded into new industries – including blinds, awnings and advanced textiles, demand surged. The business scaled rapidly, employing up to 23 people and exporting globally.

However, like many Australian manufacturers, Aeronaut Automation has more recently faced significant pressure from overseas competition, rising costs and a global economic slowdown.

For Steve, and now fellow PKF Partner Jackie Marriott, the focus shifted from growth to resilience.

This included:

• Restructuring operations to match reduced demand
• Cash flow forecasting and short-term survival planning
• Workforce right-sizing while protecting long-term capability
• Supporting difficult but necessary commercial decisions

When the advisory relationship transitioned from Steve to Jackie in 2025, Jackie stepped in with speed, responsiveness and confidence, providing hands-on support during a period of contraction and strategic reassessment.

“When the chips are down, that’s when you really need the support. Jackie has been incredibly proactive – helping us plan the small, practical steps to keep the doors open.

“She responds immediately, she’s on the front foot, and she really knows her stuff. I have full confidence in her.”

Reinvention, succession and working smarter

Today, Aeronaut Automation is evolving once again.

Rather than competing purely on cost-intensive manufacturing, the business is:

• Shifting towards outsourced production
• Leaning further into software and technology
• Preparing for intergenerational transition, with their son Michael returning to lead the next phase

PKF is supporting this transition by helping the business:

• Reconfigure its cost base
• Plan for founder retirement
• Position the business for long-term sustainability under new leadership

Additionally, despite the business’s size (now a team of 14), Aeronaut Automation’s technology is used by some of the world’s most advanced organisations.

Recently, machines designed and built in NSW were used by NASA and SpaceX suppliers to cut space suits and parachutes for a critical astronaut return mission.

For a micro-Australian manufacturer, it’s an extraordinary achievement, and one that reinforces the value of backing innovation with strong financial foundations.

Steve said, “Aeronaut Automation’s journey highlights a core belief at PKF, great businesses don’t just need accountants – they need advisers who understand the whole picture.”

Through growth, downturns, reinvention and succession, our role has been to:

• Ask the right questions
• Provide clear, timely advice
• Support decision-making when it matters most

As of October 2025*.

Looking for an adviser who can support your business through every stage?

Whether you’re scaling, restructuring, planning succession or navigating uncertainty, PKF partners with business owners to help them make confident, informed decisions.

Talk to PKF today about how we can support your business journey.