Starfighters Space, Inc. (NYSE American: FJET) will conduct the first captive-carry flight test of its STARLAUNCH 1 suborbital development vehicle using a Lockheed F-104 Starfighter in December 2026. The mission marks the program’s transition from ground-based design to active flight testing, establishing operational procedures for future drop tests and powered launches.

In a press release issued on October 13, 2026, the company confirmed that the airframe design for STARLAUNCH 1 has been finalized and inert flight hardware has been ordered. The December 2026 flight will originate from the company’s base at the National Aeronautics and Space Administration (NASA) Kennedy Space Center and proceed to the Federal Aviation Administration (FAA) licensed Cecil Spaceport in Jacksonville, Florida.

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Transitioning to active flight testing

The upcoming captive-carry flight represents a critical milestone for the STARLAUNCH program. Inert flight hardware is expected to arrive at the Kennedy Space Center hangar in November 2026. Engineering teams will then begin assembly and testing of the rocket-aircraft interface to ensure the Lockheed F-104 Starfighter can safely carry the suborbital vehicle.

Tim Franta, CEO of Starfighters Space, stated that the planned captive-carry flight will move STARLAUNCH 1 from design and ground-based development directly into flight testing.

“Our approach is deliberately incremental: build the hardware, integrate it with the aircraft, fly it, collect data, and use those results to advance toward separation and powered flight. This work on STARLAUNCH 1 is also expected to generate engineering and operational experience to inform the future development of STARLAUNCH 2.”

The December 2026 mission is designed to test aircraft integration, evaluate aerodynamic behavior, and establish operational procedures. Piercarlo Ciacchi, Director of Flight Operations and Chief Pilot of Starfighters Space, noted that the flight will capture essential data for the FAA and the United States Space Force (USSF).

“December’s captive-carry mission would essentially be step one of a multi-flight campaign, building processes for our launch team while capturing data for the FAA and the Space Force as we move toward propulsive air launch.”

Following the December 2026 captive-carry mission, the company plans to conduct a drop test over the Atlantic Ocean. This will be followed by a demonstration of the integrated propulsion system.

Hardware integration and propulsion development

The December 2026 flight may also serve a dual purpose by incorporating hardware from the company’s Wind Tunnel in the Sky program. On October 8, 2026, Starfighters Space announced the completion of its first flight hardware for this initiative, manufactured by Italian engineering firm Robby Moto Engineering S.R.L. (RME). The assembled flight articles measure 3.65 meters in length and 178 millimeters in diameter.

During the STARLAUNCH 1 flight, the company may fly this newly completed Wind Tunnel in the Sky hardware under the opposite wing of the Lockheed F-104 Starfighter on a customer-funded rideshare mission. In this configuration, the hardware will simultaneously serve as an aerodynamic counterweight for the STARLAUNCH 1 vehicle.

Propulsion development is also advancing in parallel. On September 9, 2026, Starfighters Space signed a Memorandum of Understanding with Florida-based Vaya Defense & Space to evaluate the Vortex-Hybrid rocket engine for the STARLAUNCH system. Data collected during the December 2026 flight will support Vaya Defense & Space in developing a hybrid rocket motor aligned with the specific requirements of STARLAUNCH 1.

The STARLAUNCH development pathway

Starfighters Space operates the world’s only commercial fleet of flight-ready Mach 2+ supersonic aircraft. Based at the Kennedy Space Center, the company utilizes its fleet to provide pilot training, in-flight testing, and microgravity research, while actively developing air-launch capabilities for space payloads.

The STARLAUNCH program is the company’s primary air-launch initiative. STARLAUNCH 1 serves as the initial suborbital development vehicle, designed to pave the way for STARLAUNCH 2, a larger vehicle intended for orbital launches.

The program has met several technical milestones throughout the year. On January 21, 2026, the company announced the successful completion of subsonic and supersonic wind tunnel testing for STARLAUNCH 1. These tests demonstrated clean separation behavior at Mach 0.85 and Mach 1.3. Subsequently, on February 20, 2026, the program advanced to a Critical Design Review (CDR) with support from GE Aerospace to confirm design maturity.

Addressing the hypersonic testing bottleneck

The aerospace and defense industries are currently facing a significant bottleneck in hypersonic testing. Traditional ground-based wind tunnels are heavily oversubscribed and typically offer only seconds of test time per run. Airborne platforms like the Lockheed F-104 Starfighter fleet offer sustained testing at speeds exceeding Mach 2 in real atmospheric conditions.

This capability provides a complementary method to compress development timelines for defense primes and commercial space companies, allowing them to gather sustained aerodynamic data outside of traditional laboratory environments.

AirPro News analysis

We view the activation of the STARLAUNCH flight test campaign as a notable indicator of the shifting economics in high-speed aerospace testing. By utilizing legacy supersonic platforms to bypass the constraints of ground-based infrastructure, commercial operators are positioning themselves to capture overflow demand from defense primes and space launch developers. If the December 2026 captive-carry flight successfully validates the aerodynamic integration, it will likely accelerate the timeline for propulsive air-launch systems, offering a viable alternative to traditional vertical launch architectures for smaller payloads.

The dual-use nature of the December 2026 flight, which tests the launch vehicle while simultaneously flying a commercial payload as a counterweight, demonstrates a highly efficient approach to flight test monetization. This strategy allows the operator to offset development costs while proving out multiple distinct business lines on a single sortie.

Luxembourg-based startups Space Cargo Unlimited has secured a contract with SpaceX to launch a one-tonne modular space factory aboard the new Starfall reentry capsule. The mission, targeted for 2028, marks a significant capacity increase for commercial in-space manufacturing and establishes the company as the first known European customer for the Starfall vehicle.

Announced on September 15, 2026, the agreement will utilize Space Cargo Unlimited’s BentoBox payload platform to produce materials in Low Earth Orbit (LEO) before returning them to Earth. According to Reuters, the startup is currently in discussions with more than 100 potential customers, with approximately 40 percent originating from the life sciences and biotechnology sectors.

Scaling up microgravity production

The upcoming 2028 mission represents a tenfold increase in payload capacity for Space Cargo Unlimited. The company previously operated missions with a 100-kilogram limit. The Starfall contract expands that capacity to 1,000 kilograms, or one metric ton.

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In a press release detailing the agreement, Space Cargo Unlimited Co-founder and CEO Nicolas Gaume highlighted the historical barriers to orbital production.

“For more than thirty years, we’ve known that manufacturing in microgravity can create materials and products that simply cannot be produced on Earth. The challenge has never been the science. The challenge has been making access commercially practical, repeatable and scalable.”

Demand for the expanded capacity appears robust. Reporting by Payload indicates that Space Cargo Unlimited has already sold one-third of its 1,000-kilogram allocation for the 2028 flight.

Starfall and the commercialization of Starship

The Space Cargo Unlimited contract is part of a broader commercial rollout for SpaceX’s Starfall reentry vehicle, which is designed to fly on the heavy-lift Starship launch system. SpaceX conducted the first demonstration mission of the Starfall capsule on a Falcon 9 rocket on June 23, 2026.

Other aerospace integrators are also securing space on future Starfall flights. In August 2026, Redwire subsidiary SpaceMD announced plans to fly 32 variants of its PIL-BOX payloads on a 2028 Starfall mission to research microgravity drug development. On September 21, 2026, German launch integrator Exolaunch confirmed an agreement for a Starfall mission scheduled for no earlier than 2029.

SpaceX is actively transitioning the Starship program from developmental testing to revenue-generating operations. Speaking to the vehicle’s long-term capabilities, SpaceX CEO Elon Musk noted the company’s aspirations are to deliver well over one million tons to orbit annually.

While Space Cargo Unlimited has publicized the 2028 target for its BentoBox mission, SpaceX has not officially confirmed the specific timetable for this flight.

AirPro News analysis

We view the transition from 100-kilogram research payloads to one-tonne commercial batches as a critical threshold for the in-space manufacturing sector. The high concentration of prospective biotechnology customers suggests that pharmaceuticals and advanced materials will likely drive the initial economic viability of orbital factories. If SpaceX can maintain the projected 2028 timeline for Starfall operations, the bottleneck for microgravity manufacturing will shift from launch availability to payload integration and terrestrial market demand.

Sources: Space Cargo Unlimited

Astral Materials has selected Dawn Aerospace to conduct up to 100 microgravity test flights using the Aurora spaceplane to accelerate the development of next-generation semiconductor manufacturing hardware. The campaign, announced on September 1, 2026, will operate out of the Infinity One Oklahoma Spaceport in Burns Flat, Oklahoma.

In a press release issued on September 1, 2026, Dawn Aerospace detailed the agreement, which leverages the rapid reusability of the Aurora spaceplane to provide high-cadence microgravity testing. Astral Materials plans to use these flights to refine its microgravity furnace hardware. The system is designed to reduce gravity-driven defects, such as convection and sedimentation, during the growth of semiconductor crystals. These materials have potential applications in photonics, quantum computing, and high-power electronics.

Rapid iteration in suborbital flight

The Aurora spaceplane is designed to reach a top speed of Mach 3.7 and a maximum altitude of 100 kilometers, providing payloads with up to 127 seconds of microgravity per flight. According to the manufacturers, the vehicle supports a four-hour turnaround time between flights. This operational tempo allows researchers to conduct multiple tests within a single day.

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Astral Materials Chief Technology Officer Jiya Janowitz highlighted the value of this cadence for hardware development, noting that payloads can be recovered in approximately 45 minutes.

“We can test an idea, recover it in around 45 minutes, make an adjustment on the ground and test it again later that same day. That kind of rapid iteration has never existed for microgravity manufacturing, and it fundamentally changes how quickly we can develop our technology.”

Astral Materials Chief Executive Officer Dr. Jessica Frick stated that the Aurora spaceplane provides a practical pathway to validate manufacturing systems before scaling to commercial production in orbit, where longer-duration microgravity is available.

Commercial operations and Oklahoma infrastructure

Commercial flight operations for the Astral Materials campaign are slated to begin in 2028 at the Infinity One Oklahoma Spaceport. The Oklahoma Space Industry Development Authority (OSIDA) welcomed the partnerships in an official social media statement on September 1, 2026, emphasizing the state’s focus on attracting high-cadence commercial spaceflight operations.

This agreement follows an April 16, 2026, announcement in which Dawn Aerospace and OSIDA launched the Suborbital Spaceplane Challenge. That initiative offered United States researchers up to 25 flights aboard the Aurora spaceplane to stimulate utilization of the Oklahoma facility.

Dawn Aerospace Chief Executive Officer Stefan Powell noted that routine access is required to transition microgravity manufacturing from a scientific curiosity to a viable industry, comparing the need for rapid experimentation to previous industrial revolutions.

AirPro News analysis

The partnership between Dawn Aerospace and Astral Materials highlights a critical gap in the current space manufacturing ecosystem. While orbital platforms like the International Space Station offer long-duration microgravity, the cost and lead times associated with orbital launches prohibit the rapid trial-and-error necessary for hardware development. Suborbital spaceplanes like Aurora serve as an essential stepping stone. By providing brief but frequent periods of microgravity, these vehicles allow companies to validate complex systems before committing to expensive orbital deployments.

We note a minor discrepancy in Dawn Aerospace’s published materials regarding the commencement of operations at the Oklahoma site. The main announcement targets 2028 for commercial flights, while the company’s boilerplate text references 2027. Regardless of the exact start date, establishing a reliable suborbital testbed will be vital for the commercial viability of in-space manufacturing applications.

Sources: Dawn Aerospace