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

Firefly Aerospace teams with Kratos in the DoD’s MACH-TB 2.0 program to enhance hypersonic test cadence using Alpha launch vehicle capabilities.

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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.

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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

Photo Credit: Firefly Aerospace

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Defense & Military

Firehawk Aerospace Expands Rocket Motor Production in Mississippi Facility

Firehawk Aerospace acquires a DCMA-rated facility in Mississippi to boost production of solid rocket motors using 3D-printing technology.

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This article is based on an official press release from Firehawk Aerospace.

Firehawk Aerospace Acquires Mississippi Facility to Scale Rocket Motor Production

On December 19, 2025, Firehawk Aerospace announced a significant expansion of its manufacturing capabilities with the acquisition of a specialized defense facility in Crawford, Mississippi. The Dallas-based defense technology company has secured a 20-year lease on the 636-acre site, which was formerly operated by Nammo Talley.

This acquisition marks a strategic pivot for Firehawk as it moves to address critical shortages in the U.S. defense supply chain. By taking over a facility that is already rated by the Defense Contract Management Agency (DCMA), the company aims to bypass the lengthy construction and certification timelines typically associated with greenfield defense projects. The site will serve as a hub for the full-system integration of solid rocket motors (SRMs), complementing the company’s existing R&D operations in Texas and energetics production in Oklahoma.

Strategic Asset Details

The Crawford facility is located in Lowndes County within Mississippi’s “Golden Triangle” region. According to the company’s announcement, the site is a “turnkey” defense asset designed specifically for handling high-grade explosives and munitions. The infrastructure includes assembly bays protected by one-foot-thick concrete walls and safety “blowout” walls designed to contain accidental detonations.

Because the facility was previously used by Nammo Defense Systems for the high-volume assembly of shoulder-launched munitions, such as the M72 LAW and SMAW systems, it retains the necessary regulatory certifications to allow for rapid operational ramp-up. Firehawk Aerospace CEO Will Edwards emphasized the urgency of this expansion in a statement regarding the deal.

“This acquisition strengthens Firehawk’s ability to address one of the nation’s most urgent defense challenges: rebuilding munition inventories that have been drawn down faster than they can be replaced.”

, Will Edwards, Co-founder and CEO of Firehawk Aerospace

Addressing the “Rocket Motor Crisis”

The acquisition comes at a time when the Western defense industrial base is grappling with a severe shortage of solid rocket motors, which power critical systems like the Javelin, Stinger, and GMLRS missiles. Traditional manufacturing methods, which involve casting propellant in large batches that take weeks to cure, have created production bottlenecks.

Firehawk Aerospace intends to disrupt this model by utilizing proprietary 3D-printing technology to manufacture propellant grains. According to the press release, this additive manufacturing approach reduces production times from weeks to hours. The company has explicitly stated that the new Mississippi facility is being designed to achieve a production tempo of “thousands of rockets per month,” a significant increase over legacy industry standards.

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“While the current industrial base is built to produce thousands of rockets per year, we are building this site… to operate at a much higher production tempo… designing for throughput measured in thousands per month, not years.”

, Will Edwards, CEO

Regional Economic Impact

The expansion is expected to bring skilled jobs to the Golden Triangle region, which is increasingly becoming a hub for aerospace and defense activity. Mississippi Governor Tate Reeves welcomed the investments, noting the dual benefits of economic growth and national security support.

“Their acquisition in Crawford will bring skilled jobs to the region while directly contributing to the production capacity our nation needs.”

, Tate Reeves, Governor of Mississippi

AirPro News Analysis

From R&D to Mass Production: This acquisition signals Firehawk’s transition from a development-focused startup to a volume manufacturer. By securing a pre-rated facility, Firehawk has effectively shaved 2–3 years off its timeline, the period typically required to build and certify a new explosives handling site. This speed is critical given the current geopolitical demand for tactical munitions.

Supply Chain Decentralization: The move also highlights a strategy of decentralization. By distributing operations across Texas (R&D), Oklahoma (Energetics), and now Mississippi (Integration), Firehawk is building a supply chain that may prove more resilient than centralized legacy models. This geographic diversity also allows the company to tap into distinct labor markets and state-level incentives, such as Mississippi’s aerospace initiatives.

Frequently Asked Questions

What is the significance of the DCMA rating?
A DCMA (Defense Contract Management Agency) rating verifies that a facility meets strict Department of Defense quality and safety standards. Acquiring a pre-rated facility allows Firehawk to begin production much faster than if they had to build and certify a new site from scratch.

How does Firehawk’s technology differ from traditional methods?
Traditional solid rocket motors are cast in large batches, a process that requires weeks for the propellant to cure. Firehawk uses 3D-printing technology to print propellant grains, which allows for custom geometries and reduces the manufacturing time to mere hours.

What was the facility used for previously?
The facility was formerly operated by Nammo Talley (now Nammo Defense Systems) for the assembly of shoulder-launched munitions, including the M72 LAW and SMAW systems.

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20 Years of the F-22 Raptor Operational Capability and Upgrades

Lockheed Martin celebrates 20 years of the F-22 Raptor’s operational service, highlighting its stealth, combat roles, readiness challenges, and modernization.

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Two Decades of the Raptor: Celebrating the F-22’s Operational Milestone

Lockheed Martin has launched a campaign commemorating the 20th anniversary of the F-22 Raptor achieving Initial Operational Capability (IOC). In December 2005, the 27th Fighter Squadron at Langley Air Force Base in Virginia became the first unit to field the fifth-generation fighter, marking a significant shift in global air superiority.

According to the manufacturer’s announcement, the aircraft continues to define the benchmark for modern air combat. In a statement regarding the milestone, Lockheed Martin emphasized the platform’s enduring relevance:

“The F-22 Raptor sets the global standard for capability, readiness, and mission success.”

While the airframe was designed in the 1990s and first flew in 1997, the F-22 remains a central pillar of U.S. air power. The fleet, which consists of approximately 185 remaining aircraft out of the 195 originally built, has evolved from a pure air superiority fighter into a multi-role platform capable of ground strikes and strategic deterrence.

Operational History and Combat Record

Since its operational debut, the F-22 has maintained a reputation for dominance, primarily established through high-end military aircraft exercises rather than direct air-to-air combat against manned aircraft.

Exercise Performance vs. Combat Reality

Data from the U.S. Air Force and independent observers highlights the discrepancy between the Raptor’s exercise performance and its real-world combat engagements. During the 2006 Northern Edge exercise, its first major test after becoming operational, the F-22 reportedly achieved a 108-to-0 kill ratio against simulated adversaries flying F-15s, F-16s, and F/A-18s.

Despite this lethality in training, the aircraft’s combat record is distinct. The F-22 made its combat debut in September 2014 during Operation Inherent Resolve, conducting ground strikes against ISIS targets in Syria. To date, the aircraft has zero confirmed kills against manned enemy aircraft. Its sole air-to-air victory occurred in February 2023, when an F-22 utilized an AIM-9X Sidewinder missile to down a high-altitude Chinese surveillance balloon off the coast of South Carolina.

Stealth Capabilities

The primary driver of the F-22’s longevity is its low observable technology. Defense analysts estimate the Raptor’s Radar Cross Section (RCS) to be approximately 0.0001 square meters, roughly the size of a steel marble. This makes it significantly stealthier than the F-35 Lightning II and orders of magnitude harder to detect than foreign competitors like the Russian Su-57 or the Chinese J-20.

AirPro News Analysis: The Readiness Paradox

While Lockheed Martin’s anniversary campaign highlights “readiness” as a key pillar of the F-22’s legacy, recent Air Force data suggests a more complex reality regarding the fleet’s health.

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We note that maintaining the world’s premier stealth fighter comes at a steep logistical cost. According to data published by Air & Space Forces Magazine regarding Fiscal Year 2024, the F-22’s mission capable (MC) rate dropped to approximately 40%. This figure represents a decline from roughly 52% in the previous fiscal year and indicates that, at any given time, fewer than half of the Raptors in the inventory are flyable and combat-ready.

This low readiness rate is largely attributed to the fragility of the aircraft’s stealth coatings and the aging avionics of the older airframes. The Air Force has previously attempted to retire 32 older “Block 20” F-22s used for training to divert funds toward newer programs, though Congress has blocked these efforts to preserve fleet numbers. The contrast between the jet’s theoretical dominance and its logistical availability remains a critical challenge for planners.

Modernization and Future Outlook

Contrary to earlier projections that might have seen the F-22 retired in the 2030s, the Air Force is investing heavily to keep the platform viable until the Next Generation Air Dominance (NGAD) fighter comes online.

The ARES Contract and Upgrades

In 2021, the Air Force awarded Lockheed Martin a $10.9 billion contract for the Advanced Raptor Enhancement and Sustainment (ARES) program. This decade-long modernization effort aims to update the fleet’s hardware and software.

According to budget documents for Fiscal Year 2026, the “Viability” upgrade package includes several key enhancements:

  • New Stealth Tanks: The development of low-drag external fuel tanks and pods designed to extend the aircraft’s range without compromising its radar signature.
  • Infrared Search and Track (IRST): The integration of new sensors capable of detecting heat signatures, a critical capability for engaging enemy stealth fighters that may not appear on radar.
  • Manned-Unmanned Teaming: Software upgrades intended to allow F-22 pilots to control “Collaborative Combat Aircraft”, autonomous drone wingmen, in future operational environments.

These investments suggest that while the F-22 is celebrating its past 20 years, the Air Force intends to rely on its capabilities well into the next decade.

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Sources: Lockheed Martin, U.S. Air Force

Photo Credit: Lockheed Martin

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U.S. Navy Zero-G Helmet System Completes Critical Design Review

Collins Elbit Vision Systems completes design review for the Zero-G Helmet Display, reducing pilot weight load and enhancing safety for Navy aircraft.

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This article is based on an official press release from Collins Elbit Vision Systems (RTX).

Critical Design Review Completed for Navy’s Next-Gen Helmet

Collins Elbit Vision Systems (CEVS), a joint venture between RTX’s Collins Aerospace and Elbit Systems of America, has officially announced the completion of the Critical Design Review (CDR) for the Zero-G Helmet Mounted Display System+ (HMDS+). This milestone, finalized on December 12, 2025, marks a pivotal step in the U.S. Navy’s Improved Joint Helmet-Mounted Cueing System (IJHMCS) program.

The successful CDR effectively freezes the system’s design, confirming that the helmet meets the Navy’s rigorous requirements for safety, performance, and platform integration. With the design locked, the program now transitions into the airworthiness testing and integration phase, bringing the system closer to deployment aboard the F/A-18E/F Super Hornet and EA-18G Growler fleets.

According to the press release, the Zero-G HMDS+ is engineered to address long-standing physiological challenges faced by naval aviators while introducing “6th-generation” digital capabilities to existing 4.5-generation aircraft.

Technical Leap: The Zero-G HMDS+

The Zero-G HMDS+ represents a significant departure from legacy analog systems. While previous iterations required pilots to physically attach heavy Night Vision Goggles (NVGs) for low-light operations, the new system integrates digital night vision directly into the visor. This integration streamlines cockpit operations and reduces the physical burden on the aircrew.

Weight Reduction and Pilot Safety

A primary driver for the Zero-G’s development is the reduction of head-borne weight. High-G maneuvers in fighter aircraft place immense strain on a pilot’s neck and spine, a hazard exacerbated by heavy, unbalanced legacy helmets. CEVS reports that the Zero-G system is more than 25 percent lighter than current market alternatives. Its name is derived from its optimized center of gravity, designed to minimize fatigue and long-term injury risks.

Capt. Joseph Kamara, the U.S. Navy Program Manager for Naval Aircrew Systems (PMA-202), emphasized the safety implications of the new design in a statement:

“Aircrew health and safety is our number one priority. The Zero-G being integrated through our IJHMCS program promises to relieve aircrew of neck and back strain and greatly improve ejection safety.”

Advanced Display Capabilities

Beyond ergonomics, the helmet utilizes a binocular waveguide display system. Unlike monocular reticles used in older models, this technology projects high-definition color symbology and video into both eyes, creating a fully immersive 3D view of the battlespace. The system is capable of “sensor fusion at the edge,” processing mission data and weapon information directly on the helmet to act as a primary flight instrument.

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Luke Savoie, President and CEO of Elbit Systems of America, highlighted the strategic necessity of this upgrade:

“Zero-G is providing sensor fusion at the edge… As fighter aircraft level-up, the HMDs of those systems need to as well.”

Program Timeline and Deployment

The Zero-G HMDS+ program has moved rapidly since CEVS was awarded a $16 million contract by the U.S. Navy in September 2023 for development and test support. Following the successful CDR in December 2025, the program is scheduled to undergo flight testing and Avionics integration throughout 2026 and 2027.

The U.S. Navy projects Initial Operational Capability (IOC) for the system in 2027. Once fielded, it is expected to equip aviators across the entire fleet of U.S. Navy and Royal Australian Air Force Super Hornets and Growlers, totaling more than 750 aircraft.

AirPro News Analysis

The completion of the CDR signals a critical maturity point for the Navy’s effort to modernize the human-machine interface in its tactical fleet. While much industry attention is focused on future platforms like NGAD (Next Generation Air Dominance), the Zero-G program illustrates the military’s commitment to maintaining the lethality and survivability of its existing backbone fleet.

By adapting technology originally matured for the F-35 Gen III helmet, CEVS is effectively retrofitting advanced situational awareness tools onto older airframes. This approach not only extends the combat relevance of the Super Hornet but also addresses the acute retention issue of pilot physical health. The shift to digital night vision and balanced weight distribution suggests that the Navy views pilot longevity as a critical component of fleet readiness.

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Photo Credit: RTX

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