Space & Satellites
Firefly Aerospace Alpha Rocket Explosion Delays Small Satellite Launches
Firefly Aerospace’s Alpha rocket exploded during preflight testing in Texas, causing delays and highlighting challenges in the commercial small satellite launch market.
The commercial space launch industry experienced a significant setback on September 29, 2025, when Firefly Aerospace’s Alpha rocket exploded during preflight testing at the company’s facility in Briggs, Texas. This incident represents the latest challenge facing the Texas-based aerospace company as it seeks to establish itself as a reliable player in the competitive small satellite launch market. The explosion destroyed the first stage of the rocket designated for Alpha Flight 7, marking another technical hurdle for a company that has faced multiple operational challenges since beginning orbital launch attempts in 2021.
The incident occurred during acceptance testing prior to shipping the booster to Vandenberg Space Force Base for final preparations, highlighting the complex technical challenges inherent in developing reliable launch systems for the rapidly growing commercial space sector. While no personnel were injured and safety protocols were properly followed, the loss of the booster represents a significant financial and operational setback for Firefly as it works to resume regular launch operations following a previous flight anomaly in April 2025.
Firefly Aerospace exemplifies the new generation of commercial space companies aiming to democratize access to orbit through innovative design and streamlined manufacturing. Founded in 2014 as Firefly Space Systems, the company underwent restructuring after bankruptcy in 2017 and reemerged as Firefly Aerospace under new ownership and investment. Its mission centers on providing economical, convenient access to space for small payloads through the design, manufacture, and operation of reliable launch and spacecraft vehicles.
Headquartered in Cedar Park, Texas, Firefly’s primary manufacturing and testing operations are located at a 200-acre facility in Briggs, Texas. This integrated approach allows the company to maintain control over the production process, reduce costs, and improve quality. The Briggs facility has more than doubled in size to 207,000 square feet to support increased production capacity for multiple vehicle programs.
Firefly’s strategy differs from many competitors by focusing on vertical integration and common technologies across multiple vehicle platforms, including launch vehicles, the Blue Ghost lunar lander, and the Elytra orbital vehicle. This diversified portfolio positions Firefly to serve multiple market segments within the commercial space economy. The company’s Initial Public Offering (IPO) in August 2025, with shares trading under the symbol FLY, provided additional capital to support growth and technology development. As of June 2025, Firefly employed approximately 780 people, reflecting its expansion as it scales operations to meet increasing demand.
The Alpha rocket is Firefly’s flagship offering, designed to provide dedicated launch services for payloads up to 1,030 kg to low Earth orbit at a competitive price point of $19 million per launch. The two-stage vehicle measures 29.48 meters in length, with a maximum diameter of 2.2 meters and a gross lift-off weight of 54,120 kg, placing it in the small-lift category targeting the growing demand for small satellite launches.
Alpha’s construction utilizes advanced carbon composite materials throughout the airframe, including linerless cryogenic propellant tanks that provide strength while minimizing weight. The propulsion system employs proprietary tap-off cycle engines using RP-1 kerosene and liquid oxygen. The first stage is powered by four Reaver engines (836.3 kN combined thrust), while the second stage uses a single Lightning engine (73.0 kN thrust). This design reduces part count and complexity, potentially improving reliability.
The vehicle’s payload fairing is a 2.2-meter diameter carbon composite structure with pneumatic low-shock separation systems, accommodating both dedicated and rideshare missions. Alpha can deliver 630 kg to sun-synchronous orbit at 500 km or 1,030 kg to low Earth orbit at 300 km, positioning it competitively against alternatives like Rocket Lab’s Electron. Alpha’s development history includes a redesign after bankruptcy, shifting from methalox propulsion and aerospike engines to a more conventional RP-1/LOX configuration. “Regular testing is part of Firefly’s philosophy, we test each critical component, engine, and vehicle stage to ensure it operates within our flight requirements before we ship to the launch pad.”, Firefly Aerospace official statement
The explosion that destroyed the Alpha Flight 7 first stage occurred during acceptance testing at the Briggs facility. Acceptance testing is a critical quality control phase where rocket stages are evaluated before shipment to launch sites. Firefly reported that all safety protocols were followed, no injuries occurred, and the damage was contained to the test stand area.
While the company has not disclosed the exact nature of the test, acceptance testing typically involves pressurization trials, structural load verification, and possibly limited engine firing. Security footage from a nearby business captured the explosion, providing external documentation for investigators. The damage assessment focused on the test stand, a vital piece of infrastructure for ongoing production and quality assurance.
The explosion’s timing was particularly challenging, occurring just as Firefly had received FAA clearance to resume launches following the April 2025 Flight 6 anomaly. CEO Jason Kim had recently expressed confidence in resuming operations, with Flight 7 and Flight 8 nearing readiness. The incident resets the timeline for Alpha Flight 7 and may impact production schedules depending on the extent of infrastructure damage and the time required to build a replacement first stage.
Firefly’s Alpha program has faced several technical challenges, most notably the Alpha Flight 6 failure in April 2025. During that mission, a stage separation anomaly caused the first stage to rupture, damaging the second stage and resulting in loss of mission. The root cause was identified as aerodynamic heating compromising structural integrity during a critical flight phase.
Corrective actions included increasing the thermal protection system’s thickness and adjusting the flight profile. These changes were relatively straightforward, not requiring fundamental design changes. However, the incident highlighted the complexity of developing new launch vehicles and the importance of robust ground and flight testing.
Alpha’s overall flight record reflects the challenges of new vehicle development. Its maiden flight in 2021 ended in failure, while the second flight in 2022 reached orbit but deployed satellites into a lower-than-intended orbit. The first fully successful mission was in September 2023, but subsequent flights have experienced varying degrees of success and technical issues. Industry data shows only two of six Alpha launches have been fully successful, aligning with the iterative nature of launch vehicle maturation.
“We learn from each test to improve our designs and build a more reliable system.”, Firefly Aerospace statement following the September 2025 incident
Firefly’s August 2025 IPO marked a major milestone, providing capital for expanded manufacturing, R&D, and working capital. The company reported a $1.3 billion backlog by July 2025, reflecting strong customer demand across launch services, lunar missions, and orbital vehicle operations. A key contract with Lockheed Martin, announced in June 2024, includes 15 firm launches and 10 options through 2029, potentially exceeding $400 million in value.
The company’s Briggs facility expansion and adoption of automated fiber placement technology support higher production rates and lower costs. The new system can produce all large Alpha structures in seven days, compared to previous methods, and structures for the larger Eclipse vehicle in 30 days. Alpha’s $19 million launch price positions it between Rocket Lab’s Electron and larger vehicles like SpaceX’s Falcon 9. The small satellite market, valued at $6.9 billion in 2024, is projected to grow at a compound annual rate of 16.4% through 2034. The broader commercial space launch market is also expanding, with Firefly competing against established players like SpaceX and Rocket Lab. The company’s diversified business model, including lunar landers and orbital vehicles, provides multiple revenue streams and reduces reliance on launches alone.
The commercial space launch sector has been transformed by SpaceX’s reusable launch technology and cost reductions. SpaceX accounted for 95% of US launches in 2024 and more than half of all global launches, setting aggressive pricing benchmarks. Despite this dominance, analysts recognize continued demand for diverse launch options to meet varied customer needs.
Rocket Lab is Firefly’s most direct competitor in the small satellite segment, offering reliable, lower-cost launches with Electron. Other competitors include United Launch Alliance, Arianespace, Blue Origin, and Relativity Space, each targeting different market segments. Market dynamics favor providers that can offer flexible timing, precise orbit insertion, and mission assurance in addition to competitive pricing.
The small satellite market is growing rapidly, with the number of small satellites increasing from 2,429 in 2022 to 2,860 in 2023. Nearly 61.5% of active satellites in March 2025 were classified as small satellites, creating sufficient demand to support multiple launch providers. The global space economy reached $613 billion in 2024 and is projected to exceed $1 trillion by 2032, driven by satellite constellations and new space-based services.
“We see Firefly as complementary to SpaceX. Like other transportation modes, a small/medium/large model is critical to support the diverse needs of the launch market. Not everybody wants to ride the bus.”, Jordi Paredes Garcia, Alpha Chief Engineer, Firefly Aerospace
The September 2025 explosion underscores the challenges of rocket development and the importance of rigorous ground testing. Acceptance testing is the final checkpoint before launch site operations, designed to catch defects or performance issues. The incident suggests a possible design flaw, manufacturing defect, or procedural error, which will be subject to detailed investigation.
Damage to the test stand is significant, as such infrastructure is costly and time-consuming to repair or replace. Firefly’s comprehensive testing philosophy aligns with industry best practices but also exposes hardware to potential loss before launch. The loss of the Flight 7 first stage may disrupt production momentum and planned launch cadence.
Manufacturing scalability and quality control are critical for achieving competitive launch rates and cost structures. Firefly’s investment in automation and facility expansion is intended to address these challenges, but effective implementation requires sustained execution. The company must also manage supply chain risks, regulatory compliance, and workforce retention in a highly competitive industry.
Firefly’s recent technical setbacks reflect broader industry dynamics as commercial space launch providers transition from development to operational phases. Market consolidation pressures may increase as customer requirements evolve and reliability becomes paramount. Companies that cannot demonstrate consistent operational performance may struggle to secure contracts and maintain competitive positioning. Technology trends favor automation, modularity, and standardization to reduce costs and improve consistency. Customer relationship management, regulatory compliance, and global competition will shape the industry’s evolution. Firefly’s diversified model, including lunar landers and orbital vehicles, may provide strategic advantages, but success depends on sustained execution and continuous improvement.
The September 29, 2025 explosion of Firefly Aerospace’s Alpha rocket during preflight testing is a significant setback for the company as it seeks to establish itself in the small satellite launch market. The incident highlights the persistent technical challenges and complex engineering requirements of developing reliable orbital launch capabilities. The timing, following regulatory clearance after a previous anomaly, adds to the operational and reputational challenges facing Firefly.
Firefly’s response, emphasizing safety, transparency, and a commitment to learning, aligns with industry best practices. Despite these setbacks, the growing small satellite market and global space economy provide opportunities for companies that achieve operational reliability and cost competitiveness. Firefly’s diversified business model and customer commitments offer potential, but consistent execution and technical improvement will determine its long-term viability in the evolving commercial space sector.
What caused the Firefly Alpha rocket explosion in September 2025? Was anyone injured during the incident? How does this affect Firefly’s launch schedule? How does Firefly’s Alpha rocket compare to competitors? What is Firefly’s long-term outlook? Sources: Space.com
Firefly Aerospace Alpha Rocket Explosion: Technical Setbacks and Industry Implications in Commercial Space Launch
Company Background and Strategic Position
Alpha Rocket Program Development and Technical Specifications
The September 2025 Explosion Incident Analysis
Technical Challenges and Flight History
Financial Performance and Market Position
Industry Context and Competitive Landscape
Technical and Operational Implications
Strategic Outlook and Industry Evolution
Conclusion
FAQ
The exact cause is under investigation, but the explosion occurred during acceptance testing at the Briggs, Texas facility. Acceptance testing is designed to catch defects or performance issues before shipment to the launch site.
No personnel were injured. Firefly Aerospace reported that all safety protocols were followed and the damage was contained to the test stand area.
The loss of the Flight 7 first stage will delay the mission and may impact the overall production and launch schedule, depending on the time required to manufacture and test a replacement.
Alpha is priced at $19 million per launch, offering higher payload capacity than Rocket Lab’s Electron but at a higher cost. It competes in the small satellite launch segment, targeting dedicated and rideshare missions.
Firefly’s prospects depend on its ability to resolve technical issues, achieve consistent launch reliability, and capitalize on growing demand in the small satellite and broader space markets.
Photo Credit: Ars Technica
Space & Satellites
Vast Space Selected by NASA for Sixth Private Astronaut Mission to ISS
NASA selects Vast Space for the sixth private astronaut mission to the ISS, focusing on science with a launch planned for summer 2027.
This article is based on an official press release from Vast Space.
NASA has officially selected Vast Space to conduct the sixth private astronaut mission (PAM-6) to the International Space Station (ISS). The mission, targeted for launch no earlier than summer 2027, marks a significant expansion in the commercial landscape of Low Earth Orbit (LEO). According to the announcement from the Long Beach-based aerospace company, this selection positions Vast as a key player in NASA’s strategy to transition from government-led operations to a commercial space economy.
The mission will utilize a SpaceX Falcon 9 rocket and a Dragon spacecraft to transport four private astronauts to the orbiting laboratory. While the specific crew members have not yet been named, Vast confirmed that the mission will focus heavily on science and research, distinguishing it from purely tourism-focused endeavors. This contract award represents a major milestone for Vast, which was founded in 2021 and is simultaneously developing its own commercial space station, Haven-1.
Under the terms of the agreement, the PAM-6 mission is designed to spend up to 14 days docked at the ISS. Vast stated in their press release that the primary objective is to conduct a broad range of experiments, including biology, biotechnology, physical sciences, and human research. This focus aligns with NASA’s requirement that private missions contribute to the utilization of the ISS’s research capabilities.
Vast will be responsible for the end-to-end mission management, including crew selection, training, and mission execution, subject to rigorous approval by NASA and its international partners. The company emphasized that this operational experience is critical for their long-term goals.
“Leveraging the remaining life of the International Space Station with science and research-led commercial crewed missions is a critical part of the transition to commercial space stations and fully unlocking the orbital economy.”
, Max Haot, CEO of Vast
The summer 2027 target date places PAM-6 in a busy operational window for the company. According to company timelines, Vast intends to launch its own single-module space station, Haven-1, in the first quarter of 2027. If these schedules hold, Vast could be managing two separate human spaceflight programs, one to the ISS and one to its own outpost, within the same calendar year.
Vast views the PAM-6 mission as more than just a flight to the ISS; it is an operational pathfinder for their future independent stations. By managing a crewed mission to the ISS, the company aims to refine the logistics, training protocols, and safety procedures required to operate Haven-1 and its planned successor, Haven-2. According to industry data, Vast successfully launched a “Haven Demo” pathfinder spacecraft in November 2025 aboard a SpaceX rideshare mission. That demonstration validated critical subsystems such as avionics and propulsion, likely contributing to NASA’s confidence in awarding the PAM-6 contract.
Dana Weigel, NASA’s ISS Program Manager, highlighted the agency’s goal of fostering a robust commercial market through these missions.
“By hosting private astronaut missions, the station helps accelerate innovation, opens new commercial pathways, and advances research strengthening the foundation of a thriving space economy.”
, Dana Weigel, NASA ISS Program Manager
The selection of Vast for PAM-6 signals a notable shift in the private astronaut market, which has previously been dominated by Axiom Space. Axiom operated the first four private missions to the ISS (Ax-1 through Ax-4) and holds the contract for Ax-5. By selecting a second provider, NASA appears to be actively encouraging competition and reducing reliance on a single vendor for commercial access to the station.
Furthermore, this “dual-track” strategy, where Vast pursues both ISS missions and its own station simultaneously, is aggressive. It suggests that the company is positioning itself not just as a participant in the current ISS program, but as a leading contender for the Commercial LEO Destinations (CLD) program that will eventually replace the ISS around 2030.
When will the mission launch? Who will be on board? What spacecraft will be used? How does this relate to Haven-1?
Vast Space Selected by NASA for Sixth Private Astronaut Mission to ISS
Mission Profile and Objectives
Operational Timeline
Strategic Context: The Road to Haven
AirPro News analysis
Frequently Asked Questions
The mission is targeted for launch no earlier than summer 2027.
Vast will select four crew members. Their names have not been announced, but they will undergo NASA and international partner approval.
The mission will use a SpaceX Dragon spacecraft launched atop a Falcon 9 rocket.
Vast plans to launch its own station, Haven-1, in early 2027. The ISS mission (PAM-6) serves as an operational experience builder and risk-reduction exercise for the company’s long-term habitation goals.
Sources
Photo Credit: Vast
Space & Satellites
Hypersonix Announces Launch Window for Cassowary Vex Hypersonic Mission
Hypersonix sets launch window for Cassowary Vex mission in Feb 2026 to test 3D-printed hydrogen scramjet at Mach 7 from MARS, Virginia.
Australian aerospace manufacturer Hypersonix Launch Systems has officially announced the launch window for the first flight of its DART AE (Additive Engineering) hypersonic vehicle. According to the company, the mission, codenamed “Cassowary Vex”, is scheduled to launch no earlier than late February 2026 from the Mid-Atlantic Regional Spaceport (MARS) at Wallops Island, Virginia.
This upcoming flight marks a significant milestone in the development of reusable hypersonic technologies. The mission will utilize a Rocket Lab HASTE (Hypersonic Accelerator Suborbital Test Electron) vehicle to boost the DART AE to its initial release speed. The primary objective is to validate the performance of the SPARTAN scramjet engine, a hydrogen-fueled propulsion system that is entirely 3D-printed.
The mission is being conducted in partnership with the United States Defense Innovation Unit (DIU), highlighting the deepening defense technology collaboration between the U.S. and Australia under the HyCAT (Hypersonic and High-Cadence Airborne Testing Capabilities) program.
The mission profile, detailed in recent industry reports, involves a complex sequence of events designed to test the limits of autonomous hypersonic flight. The launch vehicle, Rocket Lab’s HASTE, will lift the 3.5-meter DART AE to the upper atmosphere. Once the booster accelerates the payload to approximately Mach 5, the DART AE will separate and ignite its own engine.
According to mission specifications released by Hypersonix, the vehicle will then accelerate under its own power to a target speed of Mach 7 (approximately 8,600 km/h). The flight aims to demonstrate non-ballistic, reusable flight characteristics, distinguishing it from traditional missile tests.
The launch is set to take place at Launch Complex 2 at MARS. While the window opens in late February, Hypersonix has stated that the exact timing will be confirmed 24 hours prior to liftoff. The mission name, “Cassowary Vex,” references the flightless Australian bird, while the launch service itself has been humorously dubbed “That’s Not A Knife,” a cultural nod to the film Crocodile Dundee.
The core technology under review during this mission is the SPARTAN scramjet engine. Unlike many competitors that utilize kerosene-based fuels, the SPARTAN engine runs on green hydrogen. Hypersonix claims this fuel choice offers a higher specific impulse, resulting in greater efficiency and a clean burn that produces only water vapor. The “AE” in the vehicle’s name stands for Additive Engineering. The entire airframe and engine are constructed using high-temperature alloys, such as Inconel, capable of withstanding temperatures exceeding 1,000°C. The engine features a fixed-geometry design with no moving parts, a feature intended to increase reliability while reducing manufacturing costs.
In a statement regarding the engineering effort, Hypersonix CEO Matt Hill emphasized the collaborative nature of the project:
“This flight reflects years of engineering work and the confidence of our partners at DIU, NASA, and Rocket Lab. It brings us a meaningful step closer to operational hypersonic systems that are reusable, sustainable, and strategically relevant for Australia and for our allies.”
The “Cassowary Vex” mission arrives during a period of intense activity within the hypersonic sector. The flight is part of the DIU’s HyCAT program, which selected Hypersonix to provide a testbed capable of high-cadence testing for U.S. defense technologies.
Recent industry data places Hypersonix alongside other key players in the reusable hypersonic race. For instance, Stratolaunch successfully recovered its Talon-A2 vehicle in March 2025 after a Mach 5+ flight, and Hermeus completed the first flight of its Quarterhorse Mk 1 in May 2025. However, Hypersonix distinguishes itself by demonstrating a ground-launch capability via a rocket booster, rather than an air-launch system.
Dr. Michael Smart, Co-Founder and CTO of Hypersonix, noted the importance of real-world testing:
“DART AE allows us to validate propulsion, materials, and control systems at speeds and temperatures that simply can’t be replicated on the ground. What we learn from this mission will directly inform the next generation of operational hypersonic vehicles.”
The decision to utilize green hydrogen for the SPARTAN scramjet represents a calculated risk with potentially high rewards. While hydrogen offers superior energy density by weight compared to hydrocarbon fuels, it presents storage and volumetric challenges. If the “Cassowary Vex” mission successfully demonstrates sustained Mach 7 flight using this fuel source, it could validate hydrogen as a viable fuel for future high-speed logistics and defense platforms, moving the industry away from heavier, dirtier hydrocarbon alternatives.
Furthermore, the reliance on additive manufacturing (3D printing) for the entire airframe suggests a shift toward rapid scalability. Traditional aerospace manufacturing is often slow and tooling-intensive. By printing the vehicle from high-temperature alloys, Hypersonix is attempting to prove that hypersonic vehicles can be produced quickly and at a lower cost, a critical requirement for the “high-cadence” testing sought by the US Defense Innovation Unit.
Hypersonix’s development has been supported by significant capital investment. The company recently closed a $46 million Series A funding round. Investors include the Australian Government’s National Reconstruction Fund Corporation, the Queensland Investment Corporation, High Tor Capital (UK), and Saab (Sweden). This diverse backing underscores the international interest in the DART AE platform.
Hypersonix Sets Launch Window for Maiden “Cassowary Vex” Hypersonic Mission
Mission Profile: “Cassowary Vex”
Launch Logistics
Technology Spotlight: The SPARTAN Scramjet
Strategic Context and Market Landscape
AirPro News analysis
Financial Backing
Sources
Photo Credit: Hypersonix Launch Systems
Space & Satellites
NASA SpaceX Crew-12 Launches for Eight-Month ISS Mission
NASA’s SpaceX Crew-12 launched from Cape Canaveral with an international crew for an eight-month ISS mission focusing on medical research and tech demonstrations.
NASA’s SpaceX Crew-12 mission successfully lifted off early Friday morning, marking the beginning of an eight-month scientific expedition aboard the International Space Station (ISS). According to official reports from the space agency, the SpaceX Falcon 9 rocket launched at 5:15 a.m. EST on February 13, 2026, from Space Launch Complex 40 (SLC-40) at Cape Canaveral Space Force Station in Florida.
The mission carries a diverse international crew of four, including two NASA astronauts, one European Space Agency (ESA) astronaut, and one Roscosmos cosmonaut. The crew is traveling aboard the SpaceX Dragon spacecraft named Freedom, which successfully separated from the rocket’s second stage and achieved orbit shortly after launch. NASA confirms the spacecraft is currently executing a series of engine burns to rendezvous with the orbiting laboratory, with docking scheduled for approximately 3:15 p.m. EST on Saturday, February 14.
The Crew-12 team comprises a mix of veteran spacefarers and first-time flyers who will join Expedition 74 aboard the ISS. NASA officials highlighted the specific roles and backgrounds of the four crew members:
During their eight-month stay, the crew will conduct hundreds of experiments designed to prepare humanity for future deep-space exploration, including missions to the Moon and Mars. NASA has outlined several critical research areas for this mission.
A primary focus of the mission involves understanding how the space environment affects human health. One key study will investigate how Streptococcus pneumoniae bacteria interact with heart tissue in microgravity. According to mission documentation, bacteria can become more virulent in space, and researchers aim to identify the mechanisms behind potential long-term heart damage caused by respiratory infections.
Additionally, the crew will study fluid shifts and blood flow. This research examines how physical characteristics influence clotting risks during spaceflight, a vital dataset for mitigating health risks on long-duration missions.
The crew is also tasked with testing new life-support technologies. NASA highlights a system designed to generate intravenous (IV) fluids directly from the station’s water supply. This capability is considered critical for future Mars missions, where the logistical burden of carrying large supplies of pre-packaged medical fluids would be impractical.
The launch of Crew-12 represents a continued effort to expand the operational redundancy of commercial spaceflight infrastructure. This mission is only the second human spaceflight to launch from Space Launch Complex 40 (SLC-40). Historically used for cargo and satellite missions, SpaceX upgraded the pad to support crewed launches, providing a backup to the primary pad at Launch Complex 39A. The hardware for this mission also highlights the reusability central to the Commercial Crew Program. The Dragon capsule Freedom is making its return to space, having previously supported the Crew-4, Ax-2, Ax-3, and Crew-9 missions.
The successful utilization of SLC-40 for Crew-12 underscores a maturing commercial space ecosystem. By validating a second launch pad for human missions, NASA and SpaceX have effectively mitigated the risk of single-point ground infrastructure failure. This redundancy is essential for maintaining a continuous human presence on the ISS, especially as the station approaches its final years of operation and traffic to low-Earth orbit increases.
Furthermore, the inclusion of an ESA rookie alongside seasoned NASA and Roscosmos veterans illustrates the continued reliance on the ISS as a diplomatic and cooperative platform. Despite geopolitical tensions on Earth, the integrated crew operations required for Expedition 74 demonstrate that space remains a unique venue for international collaboration.
Crew Profile and Mission Roles
Scientific Objectives for Expedition 74
Medical and Biological Research
Technology Demonstrations
Launch Infrastructure and Hardware
AirPro News Analysis
Sources
Photo Credit: NASA
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