Saab and Divergent Technologies Unveil World’s First Software-Defined Aircraft Fuselage

Swedish defense prime Saab and California-based digital manufacturing firm Divergent Technologies have announced the completion of the world’s first “software-defined” aircraft fuselage. Unveiled on December 10, 2025, the 5-meter (16.4 ft) structure represents a significant departure from traditional aerospace Manufacturing, utilizing AI-driven design and additive manufacturing to eliminate the need for fixed tooling.

The project, spearheaded by Saab’s internal innovation startup “The Rainforest,” aims to demonstrate a rapid, flexible production capability that can iterate designs at the speed of software. According to the company’s announcement, this demonstrator fuselage is scheduled to undergo its first powered flight in 2026.

Moving Beyond Traditional Tooling

Standard aerospace manufacturing relies heavily on expensive, static infrastructure, specifically jigs, fixtures, and molds, that can take months or years to design and build. The collaboration between Saab and Divergent seeks to bypass these hardware constraints entirely.

The newly unveiled fuselage was constructed using the Divergent Adaptive Production System (DAPS). This end-to-end platform combines AI-driven topology optimization, high-volume additive manufacturing (3D printing), and automated robotic assembly. By utilizing this system, the partners report that the fuselage was built without any unique jigs or fixtures.

The resulting structure is composed of 26 unique 3D-printed metal parts, produced via Laser Powder Bed Fusion (LPBF). Saab notes that this approach reduces the part count by a factor of 100 compared to traditional riveted assemblies, which typically require thousands of fasteners and individual components.

“We envision that Saab’s future production factory is our most important product. We want to be able to give our customers freedom… We sum this up as ‘CAD in the Morning, Fly in the Afternoon’.”

, Axel Bååthe, Head of Saab’s “The Rainforest”

Strategic Implications for Defense

Saab has explicitly linked this manufacturing breakthrough to the military concept of the OODA loop (Observe, Orient, Decide, Act). In a defense context, the ability to manufacture and modify Military-Aircraft faster than an adversary provides a distinct strategic advantage. By treating the factory as a software-defined asset, Saab aims to reduce non-recurring engineering (NRE) costs and shorten lead times for new defense systems.

The fuselage features an “organic, skeletal” appearance, a characteristic of AI-generated topology optimization where material is placed only where necessary to bear loads. Beyond structural efficiency, the design integrates internal systems directly into the frame, including wiring channels and thermal management fluid routing.

“This collaboration with Saab highlights what becomes possible when ambitious aircraft concepts are paired with an end-to-end, software-defined manufacturing platform.”

, Lukas Czinger, Co-founder & CEO of Divergent Technologies

AirPro News Analysis

The shift toward “fixtureless” assembly marks a critical evolution in aerospace logistics. Historically, the “long pole” in Commercial-Aircraft production has been the tooling; if a design changes, the physical tools must be scrapped and remade, causing massive delays. By utilizing a system like DAPS, where robots use computer vision rather than physical guides to assemble parts, Manufacturers can switch between different aircraft variants, or entirely different vehicles, with simple software updates.

For defense primes like Saab, this capability suggests a future where supply chains are more resilient. Instead of relying on a fragile chain of specialized suppliers for specific brackets or panels, a software-defined factory could theoretically print and assemble mission-specific drone variants on demand, drastically reducing the logistical footprint required for military operations.

Future Milestones

Following the structural unveiling, the program is moving toward flight certification. The partners have confirmed that the fuselage is a demonstrator for a future autonomous aircraft. The next major milestone is the scheduled first flight in 2026, which will validate the airworthiness of the fully printed and robotically assembled structure.

Divergent Technologies, originally known for its work in the automotive sector with the Czinger 21C hypercar, has been steadily expanding its aerospace footprint. In addition to Saab, the company is collaborating with other major industry players, including General Atomics and Raytheon, to adapt its digital manufacturing stack for defense applications.

Sources: Saab

This article is based on an official press release from Airbus.

Germany Expands H145M Fleet to 82 Units, Solidifying Tiger Replacement Strategy

Germany has officially exercised an option to acquire 20 additional Airbus H145M helicopters, bringing the total volume of its light combat helicopter program to 82 aircraft. According to an announcement from Airbus, this move finalizes the framework contract originally signed in December 2023, marking a significant step in the Bundeswehr’s modernization efforts.

The additional rotorcraft are designated as “Leichter Kampfhubschrauber” (LKH), or Light Combat Helicopters. They are intended to serve as a critical “bridge solution” for the German armed forces, replacing the troubled Tiger attack helicopter fleet which is currently being phased out. Deliveries for the program are already underway, with the first units handed over in November 2024.

This procurement underscores the rapid pace of Germany’s “Zeitenwende” defense policy. By converting a commercially successful platform into a militarized asset, the Bundeswehr aims to restore operational readiness and combat capability on an accelerated timeline, with all 82 units expected to be delivered by 2028.

Contract Breakdown and Fleet Allocation

The execution of this option completes the acquisition structure established two years ago. The original agreement included a firm order for 62 helicopters with an option for 20 more, which has now been fully realized. According to program details, the fleet will be divided between two branches of the German armed forces:

• German Army (Heer): Will receive 72 units primarily for light attack, reconnaissance, and training roles.
• Luftwaffe (Air Force): Will operate 10 units specifically configured for Special Forces support, supplementing their existing fleet of 15 H145M SOF helicopters.

Stefan Thomé, Managing Director of Airbus Helicopters in Germany, highlighted the significance of the order in a company statement:

“We are honoured and proud that Germany has decided to order 20 additional H145M LKH helicopters. This further commitment by one of our home countries is a powerful sign of trust in the H145M’s exceptional performance and multi-role capabilities.”

Technical Capabilities: The LKH Configuration

The H145M LKH is a militarized derivative of the twin-engine H145 civil helicopter, heavily customized for the battlefield. Central to its combat utility is the HForce weapon management system, which allows the aircraft to be rapidly reconfigured from transport duties to light attack missions.

Armament and Avionics

To fulfill the anti-tank role previously held by the Tiger, the LKH fleet is being integrated with precision weaponry. The loadout options include 12.7mm machine gun pods, 20mm cannons, and 70mm laser-guided rockets. Crucially, the platform is designed to deploy the Spike ER2 anti-tank missile, providing precision strike capabilities at ranges exceeding 10 kilometers.

The aircraft are powered by two Safran Arriel 2E engines, known for their low acoustic signature, making the H145M the quietest helicopter in its class, a vital trait for special operations. The cockpit features the Helionix digital avionics suite with a 4-axis autopilot, reducing pilot workload during complex day and night operations.

Strategic Context: Replacing the Tiger

The decision to procure the H145M in such large numbers is a direct consequence of the operational challenges facing the Tiger UHT attack helicopter. Plagued by low availability rates and high maintenance costs, the Tiger is set to be retired by 2032. Rather than investing in the costly MkIII mid-life upgrade pursued by France and Spain, Germany opted for a “bridge solution” utilizing a Commercial-Off-The-Shelf (COTS) philosophy.

This shift prioritizes availability and logistics over specialized heavy armor. The H145M offers availability rates often exceeding 90%, a stark contrast to the struggles of the Tiger fleet. The new helicopters will be stationed at key bases including Bückeburg for training, Fritzlar for combat operations, and Laupheim for special forces support.

AirPro News Analysis

The execution of this option signals a pragmatic shift in German defense procurement. Historically known for lengthy development cycles and bespoke requirements, the Bundeswehr’s embrace of the H145M, a militarized civilian platform, demonstrates a new focus on speed and reliability. Delivering 82 helicopters within a four-year window (2024–2028) is an ambitious target that, if met, could serve as a model for future European defense acquisitions. However, while the H145M offers superior readiness, it lacks the heavy armor and crash survivability of a dedicated attack helicopter like the Tiger or Apache, suggesting a change in doctrine toward agility and standoff precision over close-range durability.

Frequently Asked Questions

What is the primary role of the H145M LKH?
It serves as a light combat helicopter for ground support, reconnaissance, and anti-tank warfare, acting as a replacement for the Tiger attack helicopter.

When will the deliveries be completed?
Deliveries began in November 2024 and are scheduled to conclude by 2028.

What weapons can the H145M carry?
It is equipped with the HForce system, capable of firing machine guns, cannons, guided rockets, and Spike ER2 anti-tank missiles.

Sources

• Airbus

NAVAIR V-22 Review: “Cumulative Risk” Warning and 32 Mandatory Fixes

Naval Air Systems Command (NAVAIR) released the findings of its comprehensive review of the V-22 Osprey program on December 12, 2025. While the report reaffirmed the platform’s airworthiness under current strict operational controls, it delivered a stark assessment of the fleet’s safety culture, identifying a “cumulative risk posture” that has grown unchecked since the Military-Aircraft was first fielded.

The review, which covers variants flown by the Air Force (CV-22), Marine Corps (MV-22), and Navy (CMV-22), was triggered by a series of mishaps, including the catastrophic November 2023 crash of an Air-Forces CV-22B off the coast of Japan that resulted in the deaths of eight airmen. According to the findings, the program must implement 32 distinct recommendations to address systemic failures in safety, maintenance, and supply chain management.

Systemic Issues and “Cumulative Risk”

The core finding of the NAVAIR report is that safety risks within the V-22 program have been allowed to accumulate rather than diminish over time. In mature aircraft programs, risk profiles typically decrease as the platform ages and operators gain experience. However, the review concludes that the V-22’s risk profile has increased.

Data released in the report highlights a significant disparity in how quickly the V-22 program addresses critical issues compared to other naval aviation platforms:

• Resolution Time: Critical safety and technical issues on the V-22 have gone unresolved for an average of 10 years.
• Comparison: The average time to resolve similar risks in other naval aviation platforms is approximately six years.
• Risk Ranking: The V-22 currently holds the second-highest number of “catastrophic” risk factors across all Naval Aviation platforms.

The review suggests that these delays were exacerbated by “siloed operations,” criticizing the lack of coordination between the Navy, Marine Corps, and Air Force. Differing safety standards and maintenance procedures among the services contributed to a fragmented approach to fleet safety.

Material Failure Confirmed

The report definitively confirmed the cause of the November 2023 crash. Investigators identified a material failure in the proprotor gearbox (PRGB). Specifically, “inclusions”, impurities in the steel alloy gears, led to cracking and eventual failure of the component. This finding validates earlier concerns regarding the quality control of critical drive system components.

Technical Overhaul and “Triple-Melt” Steel

To address the material failures identified in the gearbox, the program is undertaking a significant Manufacturing shift. According to the review, the program is transitioning to a “triple-melt” (VIM-VAR-VAR) forging process for critical gear components.

This advanced manufacturing technique is designed to remove impurities from the alloy. NAVAIR estimates that this process will reduce the risk of inclusions by approximately 85% to 90%. The timeline for these technical upgrades is as follows:

• Summer 2025: Depot-level installation of the new “triple-melt” gears is scheduled to begin.
• 2026: Unrestricted flight operations are expected to resume, pending fleet-wide installation.

In addition to the gearbox metallurgy, the program is deploying a redesigned input quill assembly to mitigate “hard clutch engagements,” a historic mechanical issue for the Osprey. The fleet will also see the deployment of the Osprey Drive System Safety and Health Instrumentation (ODSSHI), a network of advanced sensors capable of monitoring vibration and gear health in real-time to alert crews of potential failures.

Operational Status and Restrictions

Despite the technical roadmap, the V-22 fleet remains under significant operational restrictions as of December 12, 2025. While the aircraft is deemed airworthy, the review mandates that flights generally remain within 30 minutes of a suitable divert airfield. This restriction ensures that pilots can land quickly if a mechanical issue arises.

Furthermore, the program has established a strict flight-hour threshold for proprotor gearboxes. Any aircraft exceeding this threshold must undergo rigorous inspections or component replacement before returning to flight.

“When the V-22 Enterprise does not actively manage risks… the risks compound, increasing the likelihood of a catastrophic event.”

— Vice Adm. John E. Dougherty, NAVAIR Commander

Organizational Changes

Beyond technical fixes, the review calls for a restructuring of how the V-22 program is managed. A key recommendation is the establishment of a joint “Readiness and Safety Steering Board.” This body will be responsible for enforcing uniform Standards across the Air Force, Navy, and Marine Corps, reporting annually to top leadership to ensure accountability.

The report also outlines a shift toward a “proactive safety system.” This new approach aims to identify and fix mechanical issues before they lead to mishaps, moving the program away from the reactive posture that characterized the last decade.

AirPro News Analysis

The NAVAIR review represents a pivotal moment for the V-22 Osprey, a platform that has long been defined by its revolutionary tiltrotor capability and its troubled safety record. The admission of a “cumulative risk posture” is significant; it suggests that the bureaucracy surrounding the aircraft became desensitized to warning signs over the last decade.

While the technical solution, “triple-melt” steel, appears robust, the timeline suggests that the V-22 fleet will remain operationally hamstrung for at least another year. The challenge for NAVAIR will not just be manufacturing new gears, but enforcing the cultural changes required to break down the silos between the three services. If the new Safety Steering Board cannot enforce uniform standards, the technical upgrades may only solve part of the equation.

Frequently Asked Questions

Is the V-22 Osprey currently flying?

Yes, but with restrictions. As of December 2025, the aircraft is restricted to flying within 30 minutes of a suitable divert airfield.

What caused the November 2023 crash?

The review confirmed the crash was caused by a material failure in the proprotor gearbox due to impurities (inclusions) in the steel alloy gears.

When will the fleet return to full operations?

Unrestricted flight operations are not expected to resume until 2026, following the installation of upgraded gearbox components.

Sources

• NAVAIR / US Air Force