Firefly Aerospace joins Kratos for MACH-TB 2 0 hypersonic testing

Firefly Aerospace Joins Kratos for MACH-TB 2.0 Hypersonic Testing

We are witnessing a significant shift in the United States’ approach to defense infrastructure, specifically regarding the development of hypersonic technologies. Firefly Aerospace has officially joined the Multi-Service Advanced Capability Hypersonic Test Bed (MACH-TB) 2.0 team. This initiative, led by the Department of Defense (DoD), aims to address the critical need for increased testing cadence and affordability in hypersonic flight research. By integrating commercial launch capabilities, the program seeks to bridge the longstanding gap between ground-based testing and full-system flight environments.

The MACH-TB 2.0 program represents a strategic evolution from its predecessor, moving beyond concept validation to a scalable operational model. The initiative is managed by the DoD’s Test Resource Management Center (TRMC) and the Naval Surface Warfare Center (NSWC) Crane Division. The primary objective is to accelerate the technological maturity of hypersonic components, such as sensors, materials, and guidance systems, by leveraging commercially available launch vehicles. This approach allows for more frequent data collection compared to relying solely on expensive, full-scale weapon system prototypes.

Firefly Aerospace’s selection as a launch provider places them within a broader coalition led by Kratos Defense & Security Solutions. Kratos serves as the prime contractor for the program, having been awarded a Contracts valued at up to $1.45 billion over five years to manage Systems Engineering, Integration, and Testing (Task Area 1). As part of this team, Firefly has signed an Indefinite Delivery, Indefinite Quantity (IDIQ) contract and has already received an initial task order to execute a hypersonic test mission, signaling an immediate move toward operational readiness.

Operational Capabilities and the Alpha Launch Vehicle

The core of Firefly Aerospace’s contribution to the MACH-TB 2.0 program lies in the capabilities of its Alpha launch vehicle. Originally designed for the small satellite market, the Alpha rocket is a two-stage, all-composite vehicle that has been adapted to serve as a flexible test platform for hypersonic research. According to performance data, the vehicle is capable of accelerating payloads exceeding 1,500 kilograms to separation velocities of over 6,000 meters per second, which translates to approximately Mach 17. This performance profile is essential for simulating the extreme conditions that hypersonic weapons and vehicles encounter during flight.

Beyond raw speed, the Alpha vehicle offers the trajectory flexibility required for comprehensive testing. We understand that the vehicle can execute various mission profiles, including lofted trajectories that send payloads high into the atmosphere to test reentry dynamics, as well as depressed trajectories that fly lower and faster to simulate realistic hypersonic cruise conditions. This versatility allows the DoD to test a wide range of scenarios, from glide vehicle maneuvers to scramjet propulsion environments, using a single commercial platform.

The program also benefits from the Alpha rocket’s payload capacity, which supports “heavier and multiple-target demonstrations.” This capability implies that a single launch could potentially carry multiple experiments or deploy complex test vehicles, thereby maximizing the data return for every flight. By utilizing a vehicle with a large payload fairing, the program can accommodate the diverse needs of different DoD agencies, ensuring that the testing infrastructure remains adaptable to evolving technical requirements.

“Our Alpha launch vehicle is a natural fit for hypersonic testing, offering responsive launch solutions and custom payload accommodations that enable our customers to enhance current U.S. interceptor capabilities.”, Adam Oakes, VP of Launch at Firefly Aerospace.

Strategic Context and Industry Collaboration

The inclusion of Firefly Aerospace in the MACH-TB 2.0 team highlights a broader strategy often referred to as the “National Team” approach. Kratos has assembled a diverse coalition of subcontractors to deliver the necessary capabilities for high-cadence testing. Alongside Firefly, the team includes other industry players such as Rocket Lab, Stratolaunch, and Leidos, as well as academic partners like Purdue University. This collaborative model is designed to utilize the specific strengths of each partner, whether it be ground launch, air launch, or systems engineering, to create a robust testing ecosystem.

This developments comes at a time when the U.S. faces a strategic imperative to compete with global adversaries in the hypersonic domain. The philosophy driving MACH-TB 2.0 is one of “failing fast” and iterating quickly. To achieve this, the program aims for a high frequency of launches, with goals potentially reaching up to one launch per week. Commercial partners are pivotal to this strategy because they can provide flight opportunities at a significantly lower cost and higher availability than traditional government-owned assets.

Looking at the timeline, the momentum for this program is building rapidly. Kratos received the prime contract award in January 2025, and Firefly confirmed its task order in its Q3 2025 financial results. While Firefly is preparing for its next Alpha launch, targeted for late 2025 or early 2026, the integration into the MACH-TB 2.0 workflow suggests a busy schedule ahead. The ability to rapidly contract and deploy these missions is a key metric for the program’s success, ensuring that the U.S. can maintain a continuous pipeline of experimental data.

Conclusion

The addition of Firefly Aerospace to the MACH-TB 2.0 team marks a concrete step toward resolving the infrastructure bottlenecks that have historically slowed U.S. hypersonic development. By leveraging the Alpha launch vehicle, the DoD secures a capable and flexible platform that aligns with the urgent need for high-cadence, affordable flight testing. This Partnerships underscores the growing reliance on commercial space companies to fulfill critical national defense requirements.

As the program progresses, we expect to see a shift in how hypersonic technologies are validated, moving away from sporadic, high-stakes demonstrations toward a more iterative and data-rich testing environment. The collaboration between Kratos, Firefly, and the broader industrial base sets a precedent for future defense acquisition models, where speed and adaptability are prioritized to meet emerging global challenges.

FAQ

Question: What is the MACH-TB 2.0 program?
Answer: The Multi-Service Advanced Capability Hypersonic Test Bed (MACH-TB) 2.0 is a Department of Defense program designed to increase the frequency and affordability of hypersonic testing. It bridges the gap between ground testing and full-system flight testing by using commercial launch vehicles to test components and technologies.

Question: What is Firefly Aerospace’s role in the program?
Answer: Firefly Aerospace serves as a launch provider within the team led by Kratos Defense & Security Solutions. Firefly will use its Alpha rocket to conduct hypersonic flight tests, having signed an IDIQ contract and received an initial task order for a mission.

Question: Why is the Alpha rocket suitable for these tests?
Answer: The Alpha rocket can accelerate payloads of over 1,500 kg to speeds exceeding Mach 17. It supports various flight profiles, including lofted and depressed trajectories, and offers a large payload capacity for complex or multiple experiments.

Sources: Firefly Aerospace