This article is based on an official press release from Argonne National Laboratory.

Argonne National Laboratory and Spirit AeroSystems Unveil AI Tool for Aerospace Inspections

A new collaboration between government research facilities and private industry aims to resolve one of the most persistent bottlenecks in modern Commercial-Aircraft manufacturing: the inspection of composite materials. On January 7, 2026, Argonne National Laboratory (ANL) announced the development of an artificial intelligence tool designed to accelerate the analysis of ultrasonic scans, a move they report will significantly reduce production time and energy consumption.

The project, led by ANL in partnership with Spirit AeroSystems, Northern Illinois University, and Texas Research Institute Austin, utilizes advanced machine learning to assist human inspectors. According to the laboratory’s announcement, the tool reduces human inspection time by 7% and cuts facility-level energy usage by approximately 3% per aircraft.

Addressing the Composite Challenge

Modern aerospace engineering relies heavily on composite materials due to their superior strength-to-weight ratios. However, verifying the structural integrity of these materials is a data-intensive process. Manufacturers typically use ultrasonic non-destructive testing (NDT) to scan components, generating massive datasets that human experts must manually review to identify defects.

Argonne National Laboratory describes this manual review process as time-consuming and mentally fatiguing. To address this, the research team utilized the Argonne Leadership Computing Facility (ALCF), a U.S. Department of Energy Office of Science user facility, to develop a solution based on Convolutional Neural Networks (CNNs).

According to the technical details released by the laboratory, the AI model does not replace human inspectors. Instead, it functions as an intelligent assistant that rapidly processes scan data to highlight “regions of interest.”

“It rapidly processes scan data and highlights specific areas that contain potential defects or anomalies. This allows human experts to focus their attention solely on ‘regions of interest’ rather than reviewing empty or flawless data.”

— Argonne National Laboratory Announcement

Operational and Environmental Benefits

The integration of this technology offers measurable gains in both efficiency and Sustainability. Spirit AeroSystems, a major aerostructures manufacturer, provided the proprietary dataset of ultrasonic scans used to train the model. The resulting tool has demonstrated the ability to shorten the overall production flow time.

Efficiency Gains

By automating the initial screening of ultrasonic data, the tool reduces the time human inspectors spend on each component by 7%. In high-volume manufacturing environments, this reduction allows for increased throughput and helps alleviate production backlogs.

Energy Reduction

Perhaps most notably, the efficiency gains translate directly into energy savings. The announcement states that the tool lowers energy use by roughly 3% per aircraft. This reduction is achieved at the facility level; shorter inspection times mean that heavy machinery, HVAC systems, and lighting operate for fewer hours per unit produced.

AirPro News Analysis

The deployment of this AI tool highlights a critical shift in the aerospace sector’s approach to “Industry 4.0.” While much of the past decade’s innovation focused on physical Automation, such as robotic drilling or fastening, the current frontier is digital automation.

We observe that the bottleneck in composite manufacturing has shifted from layup (placing the material) to verification (proving the material is safe). As aircraft designs become increasingly complex, the volume of NDT data is outpacing human capacity to review it. The “human-in-the-loop” approach taken by Argonne and Spirit AeroSystems is significant because it mitigates the regulatory hurdles associated with fully autonomous inspection. By keeping the human inspector as the final authority, manufacturers can likely integrate these tools faster than if they sought to replace the human entirely.

Furthermore, the “open-framework” nature of the underlying techniques, mentioned in the release as being available for academic research, suggests that this methodology could soon expand beyond aerospace into wind energy and automotive sectors, where composite usage is also rising.

Partnership Details

The success of this initiative relied on a multi-sector collaboration. While Argonne provided the supercomputing power and machine learning expertise, Spirit AeroSystems supplied the domain knowledge and real-world data necessary to train the AI effectively. Northern Illinois University and Texas Research Institute Austin contributed to validating the technology’s robustness and reliability.

Rajkumar Kettimuthu, a Senior Scientist and Group Leader at Argonne, emphasized the collaborative nature of the work in the official release, noting the combination of industrial constraints and high-performance computing.

Sources

• Argonne National Laboratory

This article is based on an official press release from Horizon Aircraft and financial data released January 14, 2026.

Horizon Aircraft Reports $24 Million Cash Position, Confirms 2026 Prototype Timeline

Horizon Aircraft (NASDAQ: HOVR) has released its financial results for the second quarter of fiscal year 2026, ending November 30, 2025. The company reported a strengthened balance sheet with over $24 million in cash on hand, a liquidity position management states is sufficient to fund operations through the completion of its full-scale Cavorite X7 prototype in 2026.

According to the company’s official statement, the quarter was marked by significant operational growth and the securing of non-dilutive funding, positioning the aerospace manufacturer to advance its hybrid-electric Vertical Take-Off and Landing (eVTOL) technology.

Financial Highlights and Liquidity

In its Q2 fiscal 2026 report, Horizon Aircraft confirmed it has secured the necessary capital to execute its near-term engineering goals. The company highlighted a cash balance of $24 million as of November 30, 2025. This financial runway is supported by a combination of equity financing and government grants.

Recent financing activities include a capital raise of approximately C$10.8 million during the second quarter through the sale of 2.6 million shares. Additionally, analyst coverage indicates the closing of a financing tranche in December 2024 involving $1.5 million (approximately C$2.1 million) in common shares.

Beyond private capital, Horizon has successfully tapped into public funding. The company was awarded a C$10.5 million non-dilutive grant from the Initiative for Sustainable Aviation Technology (INSAT). This funding is specifically earmarked to support the development of all-weather flight capabilities for the Cavorite X7.

Brian Merker, CFO of Horizon Aircraft, commented on the company’s financial stability in the press release:

“With significantly improved working capital and incoming non-dilutive funding… we are well positioned to continue investing in our people, advancing our technology, and executing toward completion of our full-scale aircraft.”

Operational Progress: The Cavorite X7

Horizon Aircraft is focused on the development of the Cavorite X7, a seven-seat hybrid-electric eVTOL designed for regional air mobility, medical evacuation, and cargo transport. The aircraft distinguishes itself with a patented “fan-in-wing” system, which allows it to fly 98% of its mission configuration as a traditional fixed-wing plane. This design covers the vertical lift fans during forward flight to significantly reduce drag.

Prototype Timeline

The company has outlined a clear roadmap for the next 18 months. According to the Q2 update:

• 2026: Assembly of the first full-scale Cavorite X7 prototype is scheduled for completion.
• Early 2027: Initial flight testing is expected to commence.

To support this timeline, Horizon has doubled its engineering headcount year-over-year and plans to double the team size again by the end of 2026.

Brandon Robinson, CEO of Horizon Aircraft, emphasized the momentum behind the project:

“The progress achieved during the second quarter of fiscal 2026 provides strong momentum toward completing our full-scale aircraft and commencing initial testing within the next 12 to 18 months.”

AirPro News Analysis

The Hybrid Advantage in a Crowded Market

While many competitors in the Advanced Air Mobility (AAM) sector are pursuing pure electric architectures tailored for short-range urban air taxi services, Horizon Aircraft’s hybrid-electric approach targets a different segment. By utilizing a hybrid system that recharges batteries in-flight, the Cavorite X7 offers a projected range of 800 kilometers (500 miles) and speeds of up to 450 km/h (280 mph).

This technical choice allows Horizon to bypass the immediate need for extensive ground charging infrastructure, a major bottleneck for pure electric eVTOLs. Furthermore, the ability to operate in “austere environments”, areas without prepared runways, makes the aircraft particularly viable for military and medevac applications, sectors where reliability and range often outweigh the benefits of zero-emission propulsion.

Strategic Outlook

Horizon Aircraft is actively deepening relationships with supply chain partners to ensure the timely delivery of components for the full-scale prototype. The company is also exploring military applications for the Cavorite X7, leveraging its design suitability for rugged environments.

The company’s stock (NASDAQ: HOVR) has reflected the volatility typical of the emerging eVTOL sector, though the confirmation of a funded runway through 2026 provides a degree of certainty regarding the company’s ability to reach its next major technical milestone.

Frequently Asked Questions

What is the Cavorite X7?
The Cavorite X7 is a hybrid-electric Vertical Take-Off and Landing (eVTOL) aircraft being developed by Horizon Aircraft. It carries one pilot and six passengers and features a patented fan-in-wing design.

When will the Cavorite X7 fly?
According to the company’s latest schedule, the full-scale prototype will be assembled in 2026, with initial flight testing slated to begin in early 2027.

How much cash does Horizon Aircraft have?
As of November 30, 2025, the company reported $24 million in cash on hand.

What makes Horizon different from other eVTOL companies?
Horizon focuses on regional transport rather than urban air taxis. Its hybrid-electric powertrain allows for longer ranges and removes the dependency on ground charging stations.

Sources

• Horizon Aircraft Press Release

From Superjumbo to Single-Aisle: Airbus Consortium Proves “Closed-Loop” Composite Recycling is Flight-Ready

In a significant step toward a circular aviation economy, a consortium led by Airbus has successfully demonstrated that high-value thermoplastic composite parts can be recycled from retired aircraft and repurposed into structural components for new jets. The project, titled “Recycled and Ready,” involved taking an end-of-life part from a retired A380 and manufacturing it into a flight-ready component for an A320neo.

According to the official announcement released on January 15, 2026, the initiative proves that aerospace composites, historically difficult to recycle without degrading their quality, can be retained within the aviation supply chain rather than being “downcycled” into lower-value products like filler or ground transport components.

The breakthrough was achieved through a partnership between Airbus, materials supplier Toray Advanced Composites, aerostructures manufacturer Daher, and dismantling specialist Tarmac Aerosave. The team’s efforts were recognized with a JEC Innovation Award in the “Circularity and Recycling” category.

Closing the Loop: The Process

The core achievement of the project was the successful conversion of a used engine pylon fairing cover (cowl) from a dismantled A380 into a structural panel for an A320neo pylon. This transition from a “superjumbo” part to a single-aisle component validates the industrial feasibility of reusing thermoplastic materials.

The project relied on the specific properties of the material used: Toray Cetex® TC1100, a carbon fiber reinforced Polyphenylene Sulfide (PPS) thermoplastic. Unlike traditional thermoset composites, which undergo a chemical change during curing that cannot be reversed, thermoplastics can be melted, reshaped, and reformed multiple times.

Consortium Roles

The project required precise coordination across the supply-chain, with each partner fulfilling a specific role:

• Tarmac Aerosave: Managed the dismantling of the A380, developing a non-destructive process to recover the composite parts without compromising the material’s integrity.
• Toray Advanced Composites: Assessed the quality of the recovered material to ensure it met the stringent safety standards required for a “second life” in structural aerospace applications.
• Daher: Led the industrial manufacturing process, reshaping the recovered material into the new A320neo component.
• Airbus: Served as the project integrator, overseeing technical requirements and managing the certification of the recycled part for flight testing.

Industry Significance and Executive Commentary

This development addresses one of the aviation industry’s most persistent sustainability challenges: the disposal of carbon fiber composites. While metals like aluminum and titanium have recovery rates near 90%, composites have often ended up in landfills because separating the fibers from the resin is technically difficult and expensive.

Isabell Gradert, Airbus VP of Central Research and Technology, emphasized the importance of cross-industry collaboration in achieving this milestone:

“This recognition from the JEC shows how complex challenges, including high-value recycling, are best tackled through partnership. We exist in a complex aerospace supply chain in a hyper-connected world. If a company comes up with a solution on its own, that’s a great story. If an entire industry does it together, that’s transformative.”

, Isabell Gradert, Airbus VP Central Research and Technology

Advertisement

Scott Unger, CEO of Toray Advanced Composites, noted that the project opens the door for high-performance materials to be “meaningfully reused and reintegrated” into structural applications, rather than being discarded.

AirPro News Analysis

The Shift to Thermoplastics: This project underscores the strategic advantage of thermoplastic composites over traditional thermosets. While thermosets (like those used heavily on the Boeing 787 and early A350s) offer excellent strength-to-weight ratios, they are chemically “baked” and difficult to recycle. The success of the “Recycled and Ready” program suggests that future aircraft designs may increasingly favor thermoplastics to ensure end-of-life recyclability.

Supply Chain Resilience: Beyond sustainability, this approach offers a strategic benefit. By treating retired aircraft as “material mines,” manufacturers can reduce their dependence on virgin raw materials. With over 10,000 thermoplastic parts on a single A380, the potential inventory for recycled feedstock is substantial. This could help insulate manufacturers from price volatility and supply chain disruptions in the global carbon fiber market.

Frequently Asked Questions

What is the difference between thermoset and thermoplastic composites?

Thermoset composites are cured irreversibly, meaning they cannot be melted down and reshaped. Thermoplastic composites, like the PPS used in this project, can be heated, reshaped, and cooled multiple times without significant loss of mechanical properties.

What aircraft were involved in this test?

The source material came from a retired Airbus A380, and the recycled part was manufactured for an Airbus A320neo.

Who were the partners in the consortium?

The project was a collaboration between Airbus, Toray Advanced Composites, Daher, and Tarmac Aerosave.

Sources

• Airbus