Happy New Year! 2025 marked another year of progress on the DarkAero 1 prototype, with testing and validation work continuing through structural test campaigns on the landing gear and airframe. DarkAero advanced as a company through capability improvements in automation, testing, inspection, and additive manufacturing. Manufacturing capacity increased with the growth of the team, allowing for further fulfillment of contract customer projects.
DarkAero 1 Testing
Early in the year, the final phases of the landing gear structural test campaign were completed. This included drop testing, side load testing, and brake load testing, all of which informed design updates to the struts, shock mounts, and trailing link geometry. The test campaign validated the landing gear structure and the results directly guided the hardware configuration that will be used during flight testing. A video summarizing the landing gear test effort was released on YouTube:
Through the spring, testing transitioned to validation of the wing-to-fuselage connection. A key variable driving this effort was the angular deflection of the wing root ribs under load. To characterize this behavior, the wing test rig was configured to apply representative loads to the wing while measuring angular deflection at the wing roots. Because the wing would be loaded during this phase, the test campaign also served as an opportunity to batch implement and structurally validate several updates to the wing center section. These included the addition of inspection ports, stiffened flap mounting structures, and pi joints. Details of this work were captured in another YouTube video:
Once angular deflection data for the wing root ribs had been collected, testing progressed to proof loading the wing-to-fuselage connection itself. A configurable test rig was designed and built to apply loads to the wing attachment lugs and surrounding structure under simulated positive and negative g-load conditions, as well as asymmetric loading cases. The background and setup of this test were highlighted in a recently released YouTube video:
Toward the end of the year, structural testing efforts shifted to the empennage. Lateral proof load testing was performed on the empennage and vertical stabilizer. This required a dedicated test fixture that supported the airframe on its side while lateral loads were applied to the vertical stabilizer. The applied loads simulated a range of extreme aerodynamic conditions dictated by the allowable rudder control input of the pilot. Determining the appropriate proof load value for the vertical stabilizer test required discussing initial split rudder operation during flight testing. This is a unique aspect of the DarkAero 1 that the team is looking forward to further developing and eventually operating in flight. The airframe was tested in both left and right lateral directions, and the empennage and vertical stabilizer passed the testing without issue.
Collectively, these tests represent a significant body of structural validation work for the DarkAero 1 prototype. The airframe is optimized to enable missions requiring speed, range, and efficiency, and the target level of structural optimization makes validation like this especially important. Each campaign reduced uncertainty, validated critical load paths, and increased confidence in the airframe structures under representative loading conditions. Additionally, the structures are being designed for efficient manufacturing and assembly, so the overall approach extends beyond prototype-only solutions. Together, these tests mark meaningful progress toward flight testing. Remaining milestones before first flight are outlined on the DarkAero website here:
DeltaHawk-powered RV-14 first flight with firewall forward hardware supplied by DarkAero.
DarkAero Services
Throughout 2025, DarkAero Services continued to support external customers through a range of engineering, manufacturing, and testing projects. Work this year included composite airframe structures, tooling, and custom hardware, leveraging the same design, fabrication, and validation processes used in internal development programs. This contract work provided opportunities to apply and further develop in-house capabilities across diverse requirements while supporting customers with demanding technical needs.
Applications supported during the year spanned both manned and unmanned aircraft programs. Several customer projects progressed through ground testing and into flight testing, with successful flight test campaigns conducted across both categories. These efforts demonstrated the applicability of the underlying design and manufacturing approaches across a wide range of vehicle sizes, mission profiles, and operational requirements.
DarkAero team outing to Road America.
Team Growth
Team growth continued over the past year with the addition of four new manufacturing technicians. These hires scaled up manufacturing capacity and supported tooling development, hardware fabrication, and contract fulfillment.
Recruiting efforts remained active for both engineers and technicians. Emphasis has been placed on individuals with a strong work ethic, hands-on skills, and an interest in tackling technically challenging projects. This continued growth reflects the need to support ongoing aircraft development, customer work, and expanded manufacturing capabilities as programs advance toward flight testing and production readiness.
Expansion of Capabilities
Throughout 2025, in-house engineering and manufacturing capabilities were amplified at DarkAero through the addition of several major pieces of equipment. These investments were made with a focus on improving automation, testing, inspection, and additive manufacturing across both prototype and customer work.
One of the most significant additions was an Autometrix Carbon automated cloth cutting table, which enables precise, repeatable cutting of composite plies directly from digital patterns. This system improves material utilization, reduces variability in layups, and supports structural optimization by ensuring consistent ply geometry across test articles and flight hardware.
To support structural validation and material characterization, a test machine was added to enhance in-house mechanical testing capability. This allows coupon and subcomponent testing to be performed internally, shortening feedback loops between design, fabrication, and validation while increasing confidence in material properties and joint behavior.
Metrology capability was also substantially advanced with the addition of a FaroArm and 3D scanning system. These tools provide high-resolution measurement of parts, tooling, and assemblies, enabling direct comparison to CAD models and improving verification of complex composite geometries. The ability to accurately measure structures and tooling is an important part of quality control.
In support of rapid iteration and tooling development, a Vision Miner 22 IDEX V3 large-format 3D printer was brought online. This system is used extensively for producing high temperature tooling, fixtures, test hardware, and custom shop aids. The dual extruder configuration enables efficient printing of complex geometries, further accelerating development cycles.
Together, these additions strengthen DarkAero’s ability to design, build, measure, and test complex composite structures in-house. They reduce reliance on external vendors, improve development speed, and provide a more tightly integrated path from concept to validated hardware. These are all benefits that directly support DarkAero 1 development as well as ongoing contract work.
Courses
Three sessions of the DarkAero Aerospace Composites Course were held in 2025, with students attending to deepen their understanding of composite materials and manufacturing techniques for applications ranging from hobby projects to commercial products. The course has now been run for more than four years, with the curriculum continually refined and expanded based on hands-on experience, student feedback, and ongoing development work.
Participants in the 2025 sessions brought a wide range of projects and backgrounds, including work related to eVTOL aircraft, kitplanes, seaplanes, marine structures, rockets, robotics, and medical hardware. This diversity of applications reinforced the versatility of composite materials and highlighted common engineering challenges across industries, providing valuable context for both instruction and discussion.
The courses continue to emphasize practical, experience-driven instruction, focusing on real-world manufacturing processes, and design considerations. In addition to supporting external students, the course structure and material also serve as a knowledge base for internal training, helping reinforce consistent composite manufacturing practices as in-house capabilities continue to expand.
Two sessions of the courses are on the horizon for 2026. Sign up using the links below:
Looking Ahead
Heading into 2026, focus will remain firmly on the remaining DarkAero 1 system design and validation work, accepting prototype hardware for flight, and continuing to build the team and tools required to support both DarkAero 1 flight testing and future kit production.
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