Military Technology
Aurora Flight Sciences Advances X-65 with Active Flow Control Technology
Aurora Flight Sciences and DARPA progress on X-65, an aircraft using Active Flow Control to replace traditional control surfaces, targeting 2027 flight.
The Evolution of Flight Control: X-65 and the Shift to Active Flow Control
The aviation industry is currently witnessing a significant shift in aerodynamic design, moving away from the mechanical control surfaces that have defined flight for over a century. On November 20, 2025, Aurora Flight Sciences, a Boeing company, announced a critical milestone in the development of the X-65. This experimental military aircraft, developed under the Defense Advanced Research Projects Agency (DARPA) CRANE program, represents a fundamental departure from traditional aircraft architecture. Rather than relying on external moving parts like rudders, flaps, and ailerons, the X-65 is designed to maneuver using bursts of compressed air, a technology known as Active Flow Control (AFC).
The significance of this development lies in its potential to alter the basic mechanics of flight. Since the Wright brothers, aircraft have been steered by physically altering the shape of the wing or tail to change airflow. The X-65 program aims to prove that this can be achieved more efficiently and stealthily through pneumatic systems. As the program progresses, the focus has shifted to the manufacturing phase, with substantial hardware taking shape at production facilities. This transition from digital design to physical assembly marks a pivotal moment for the Control of Revolutionary Aircraft with Novel Effectors (CRANE) program.
We are observing a careful yet ambitious timeline for this project. While the engineering challenges inherent in such a novel design have necessitated schedule adjustments, the commitment to validating AFC technology remains steadfast. The recent updates from Aurora Flight Sciences provide a transparent view into the production status, the restructuring of the program’s investments model, and the technical specifications that define this unique X-plane. Understanding these details offers insight into the future of military and potentially commercial aircraft.
Manufacturing Milestones and Program Restructuring
According to the latest reports from November 2025, the manufacturing of the X-65 has reached an advanced stage. The aircraft’s fuselage is currently being assembled at Aurora’s facility in Bridgeport, West Virginia. Projections indicate that the fuselage is on track for completion in January 2026. Alongside the main body, fabrication of the wing assemblies and engine diffusers is proceeding, while critical propulsion and AFC system components have already been received and are prepared for integration. This synchronization of component manufacturing suggests that despite broader timeline shifts, the physical construction is proceeding with momentum.
The program has also undergone a strategic restructuring to ensure its viability amidst rising costs and technical complexities. In August 2025, DARPA and Aurora Flight Sciences finalized a new agreement to co-invest in the completion of the X-65. This shift from a purely government-funded model to a shared investment structure highlights the industry’s stake in the success of this technology. It acknowledges the resource-intensive nature of developing an entirely new method of flight control and secures the necessary capital to push the project through its ground testing and flight demonstration phases.
Regarding the timeline, the schedule has been adjusted to accommodate these changes and the rigorous demands of safety and systems integration. Following the targeted completion of the fuselage in early 2026, the program is scheduled to move into ground testing later that year or in early 2027. Consequently, the first flight of the X-65, originally anticipated earlier, is now projected for late 2027. This revised schedule reflects a pragmatic approach to experimental aerospace development, prioritizing system reliability over speed.
“We’re excited to continue our longstanding partnership with DARPA to complete the build of the X-65 aircraft and demonstrate the capabilities of active flow control in flight. The X-65 platform will be an enduring flight test asset, and we’re confident that future aircraft designs… will be able to leverage the underlying technologies.”, Larry Wirsing, VP of Aircraft Development at Aurora Flight Sciences.
Technological Innovation: Active Flow Control
The core innovation driving the X-65 is Active Flow Control (AFC). In a standard aircraft, the pilot steers by moving hinged panels on the wings and tail. These movements create drag and require heavy, complex hydraulic systems. The X-65 replaces these mechanical surfaces with 14 specialized “effectors” embedded across the flying surfaces. These effectors release pressurized bursts of air to manipulate the aerodynamic flow over the wings, effectively changing the air pressure and flow direction to control pitch, roll, and yaw.
The implications of this technology extend beyond simple maneuverability. By eliminating the gaps, hinges, and actuators associated with moving control surfaces, aircraft designers can create smoother, more seamless wing structures. This reduction in mechanical complexity translates to lower weight and reduced drag, which can improve fuel efficiency and range. Furthermore, the absence of external moving parts significantly reduces the aircraft’s radar cross-section, offering inherent stealth advantages that are highly valuable for military applications.
To validate this technology safely, the X-65 is being built with a “training wheels” philosophy. The aircraft is equipped with both traditional mechanical controls and the new AFC system. In the initial phase of flight testing, the aircraft will utilize standard flaps and rudders to establish baseline performance and ensure safety. Once the flight envelope is secured, the mechanical controls will be locked down, and the aircraft will rely solely on the air-burst effectors. This phased approach allows engineers to isolate the performance of the AFC system and prove its viability as a primary control method.
Specifications and Operational Context
The X-65 is a substantial unmanned system designed to operate at speeds and altitudes relevant to real-world applications. The aircraft features a wingspan of 30 feet (approximately 9 meters) and a gross weight of 7,000 pounds (approximately 3,175 kilograms). It is powered by a single turbojet engine and is capable of reaching speeds up to Mach 0.7 (approximately 537 mph). The design utilizes a modular “diamond-like” wing shape, which allows for outboard sections to be swapped. This modularity ensures that the X-65 can serve as a long-term testbed, testing different AFC configurations in the future without requiring a completely new airframe.
It is important to distinguish the X-65 CRANE program from other ongoing developments at Aurora, such as the SPRINT program. While both involve advanced aerodynamics, the SPRINT program focuses on “fan-in-wing” technology for vertical takeoff and landing. The X-65 is distinct in its singular focus on replacing control surfaces with pneumatic steering. This distinction is vital for understanding the specific engineering goals of the CRANE program, which is to validate AFC for broad adoption across future aircraft generations.
“Demonstrating active flow control in flight opens new design and production possibilities for both military and commercial aircraft.”, Christopher Kent, DARPA CRANE Program Manager.
Future Implications and Conclusion
The progress of the X-65 signals a potential transformation in aerospace engineering. If the flight tests scheduled for late 2027 are successful, the data gathered could lead to a new generation of aircraft that are lighter, stealthier, and more efficient. The collaboration between DARPA and Aurora Flight Sciences demonstrates a shared commitment to overcoming the technical hurdles associated with radical innovation. By co-investing in this technology, both parties are betting on a future where the moving wing flap becomes a relic of the past.
As the fuselage nears completion in West Virginia, the industry watches closely. The successful implementation of Active Flow Control would not only enhance military capabilities through improved stealth and performance but could eventually filter down to commercial aviation, offering fuel savings and design efficiencies. The X-65 serves as the critical bridge between theoretical aerodynamics and practical, operational reality.
FAQ
What is the X-65?
The X-65 is an experimental unmanned aircraft developed by Aurora Flight Sciences and DARPA to demonstrate Active Flow Control (AFC) technology, which replaces traditional moving control surfaces with bursts of compressed air.
When is the X-65 expected to fly?
Following schedule adjustments, the first flight of the X-65 is currently projected for late 2027, with ground testing expected to begin in late 2026 or early 2027.
How does the X-65 steer without moving parts?
It uses 14 “effectors” embedded in the wings that release pressurized air bursts. These bursts manipulate airflow over the aircraft surfaces to control pitch, roll, and yaw, replacing the need for flaps and rudders.
Sources: Aurora Flight Sciences
Photo Credit: Aurora
Military Technology
Honeywell Aerospace and Shield AI Complete Autonomous ISR Mission
Honeywell Aerospace and Shield AI completed a two-aircraft autonomous ISR mission near Phoenix after just six weeks of Hivemind platform training.
Honeywell Aerospace and Shield AI have successfully completed two autonomous flight demonstrations, culminating in a coordinated intelligence, surveillance, and reconnaissance (ISR) mission on October 8, 2026, near Phoenix, Arizona.
The milestone, announced in a press release on October 13, 2026, highlights the rapid integration of advanced autonomy using open architecture technologies, with Honeywell engineers achieving their first autonomous flight after just six weeks of training on Shield AI’s Hivemind Enterprise platform.
Rapid autonomy integration and flight milestones
The autonomy development effort began in late April 2026 when Honeywell Aerospace’s team started training on the Hivemind Enterprise platform. By mid-June 2026, the team flew a BFD-SE8 multirotor aircraft autonomously for the first time. This development process was originally estimated to take 54 weeks before the integration of the Hivemind system.
The first official autonomous flight demonstration took place on July 8, 2026, in Plymouth, Minnesota. During this event, the aircraft autonomously executed a planned mission that included dynamic rerouting around a designated no-fly zone.
The program advanced to a multi-aircraft operation on October 8, 2026. Two aircraft running the Hivemind software completed a coordinated ISR mission near Phoenix, Arizona. The aircraft autonomously shared target information and divided mission responsibilities without human intervention.
Tom Schaefer, Vice President of Hivemind Enterprise at Shield AI, highlighted the efficiency of the integration process:
“Honeywell Aerospace engineers flew their first autonomous aircraft within weeks, work their engineering leads estimated would normally take a year. Hivemind Enterprise handled the autonomy basics, so the team could spend its time on its own detection and tracking model. We built Hivemind so partners can work this way.”
The Hivemind platform and open architecture
The Hivemind Enterprise platform packages Shield AI’s development environment with its onboard autonomy software. It provides core functions such as route planning, mission management, and aircraft-to-aircraft communication. The system is designed to enable swarms of drones and aircraft to operate autonomously without GPS, communications, or a human pilot.
The autonomous flights integrated Honeywell Aerospace’s o480 inertial navigation system and Anthem avionics portfolio with the Shield AI software stack.
Todd Giles, Senior Vice President of Engineering and Chief Technology Officer at Honeywell Aerospace, emphasized the broader implications for the industry:
“Open architectures are changing the pace of innovation in aerospace, and this milestone demonstrates how Honeywell Aerospace can rapidly translate advanced autonomy into real-world capability. By combining our expertise in avionics, navigation, sensing and autonomy, we are helping create a scalable foundation for the next generation of autonomous aircraft and mission systems.”
Honeywell Aerospace’s independent trajectory and Shield AI partnership
The collaboration between the two companies was formalized on July 22, 2026, with a Memorandum of Understanding signed at the Farnborough International Airshow. The agreement focuses on developing a trusted autonomy software stack on Shield AI’s Hivemind Software Development Kit.
The autonomous flight milestones follow a major corporate transition for Honeywell Aerospace. On June 29, 2026, the company completed its spin-off from parent company Honeywell International. It now operates as an independent, publicly traded company on the Nasdaq under the ticker symbol HONA. Headquartered in Phoenix, Arizona, the tier-1 aerospace and defense supplier employs over 36,000 people and serves more than 10,000 global customers.
Shield AI, a venture-backed defense technology company based in San Diego, California, has seen increasing adoption of its AI pilots. The Hivemind system has piloted more than 40 different platforms to date, including F-16 fighter jets, Helicopters, and ground vehicles. On October 7, 2026, Shield AI and Kraken Technology Group demonstrated autonomous maritime teaming by integrating Hivemind onto uncrewed surface vessels in Portsmouth, United Kingdom.
AirPro News analysis
The reduction of an autonomy development cycle from an estimated 54 weeks to just six weeks is a material shift in how aerospace primes integrate third-party artificial intelligence. As defense sectors globally push for the rapid deployment of autonomous systems in contested environments, the bottleneck has often been the bespoke integration of flight control and mission management software. By utilizing an open architecture platform that handles baseline autonomy, tier-1 suppliers like Honeywell Aerospace can focus engineering resources on proprietary sensor integration and specific mission capabilities. We view this successful multi-aircraft demonstration as a validation of the open-systems approach, likely accelerating the timeline for fielding collaborative combat aircraft and autonomous ISR swarms.
Photo Credit: Honeywell Aerospace
Military Technology
Whisper Aero eQ250 Completes First Crewed Flight Tests
Whisper Aero reaches TRL 7 with eQ250 electric ducted fans after crewed flights in Tennessee, recording 52 dB(A) at 100 feet.
Whisper Aero has successfully completed the first crewed flight tests of its eQ250 electric ducted fans, achieving a Technology Readiness Level greater than 7 and clearing the path for integration into upcoming Military-Aircraft and civil aircraft programs.
The mid-August 2026 test campaign took place at Crossville Memorial Airport (KCSV) in Tennessee. According to official statements released on August 19, 2026, by Whisper Aero and the Tennessee Department of Economic and Community Development, the flights validated the ultra-quiet acoustic signature of the propulsion system in real-world conditions.
Flight test campaign and acoustic performance
The test vehicle, designated the Whisper Powered Swift, is a modified Aériane Swift 3 glider with a 46-foot wingspan. Whisper Aero retrofitted the airframe with two 10-inch eQ250 propulsors, each capable of producing up to 85 pounds of static thrust. Power was supplied by five Electric Power Systems EPiC 1.0 battery modules.
Test pilot Zac Majors conducted three flights totaling more than 130 minutes in the air. The crewed flights followed a phased testing progression that included progressively ballasted glider flights, aircraft integration testing, formal readiness reviews, and more than 1,000 hours of ground-based Propulsion life testing.
Acoustic measurements taken during early morning flights demonstrated the low noise profile of the eQ250 fans. With an ambient noise level of 34 dB(A), the aircraft produced only 52 dB(A) while flying at an altitude of 100 feet.
“Any new technology needs strong proof points. This is a very strong proof point. These propulsors are absolutely as quiet as we said they are.”
Whisper Aero Chief Executive Officer Mark Moore noted that adding the propulsors to a glider allowed the company to demonstrate that the engines at full throttle add virtually no noise to the baseline acoustic signature of the airframe.
Chief Operating Officer Ian Villa detailed the regulatory and safety steps preceding the flights. The company processed the modifications through its AS9100 quality management system and secured a special airworthiness certificate from the Federal Aviation Administration (FAA) before commencing the powered flight phase.
Defense applications and future development
Reaching Technology Readiness Level (TRL) 7 indicates that the eQ250 propulsors have been demonstrated in an operational environment and are ready for deployment on partner aircraft. Whisper Aero is currently involved in multiple defense programs that will utilize this propulsion technology.
In June 2026, the US Defense Innovation Unit (DIU) awarded a Contracts to Mach Industries and Whisper Aero for the Runway Independent Maritime Expeditionary Strike (RIMES) program. The companies are co-developing a hybrid-electric prototype aircraft named Atlas, which is designed to launch from ships lacking large flight decks.
Whisper Aero is also under contract with the US Air Force to develop the Collaborative Logistics Aircraft (CLA). This family of autonomous aircraft is intended for contested logistics operations, with initial testing scheduled for 2027.
The recent flight tests in Tennessee were supported by a $500,000 Transportation Network Growth Opportunity grant awarded to Tennessee Tech University by the Tennessee Department of Economic and Community Development in April 2025. Following the successful flights in Crossville, Whisper Aero plans to conduct further acoustic measurement tests and evaluations with government customers at White Sands Missile Range in New Mexico later this year.
AirPro News analysis
We view the use of a modified glider as a highly effective method for isolating propulsion noise during acoustic testing. By establishing a baseline with the unpowered Aériane Swift 3, Whisper Aero generated clean data proving that the eQ250 fans do not significantly increase the airframe’s overall noise footprint. Achieving TRL 7 is a critical milestone for any aerospace Startups, as it transitions the technology from experimental status to a viable product for integration. The immediate application of these propulsors in the DIU RIMES and USAF CLA programs highlights the strong demand for low-acoustic-signature propulsion in military logistics and expeditionary roles.
Sources: Whisper Aero
Photo Credit: Whisper Aero
Military Technology
Saab Unveils A3-001 Supersonic Stealth Drone Concept
Saab revealed the A3-001 uncrewed combat air system concept at Malmen Air Base, targeting mid-2030s operations alongside the Gripen E.
Saab AB unveiled a full-scale concept model of a supersonic, low-observable uncrewed combat air system, designated the A3-001, during the Jubilee Air Show at Malmen Air Base in Linköping, Sweden, on August 22, 2026.
The presentation, which coincided with the 100th anniversary of the Swedish Air Force, outlines the manufacturers vision for a high-end autonomous platform designed to operate alongside crewed fighters like the Saab Gripen E. According to a company press release, the A3-001 is intended for high-risk missions in heavily defended airspace, including electronic warfare, suppression of enemy air defenses (SEAD), and precision strikes.
Pathway to the A3-001 concept
While the A3-001 represents a future operational vision targeted for the mid-2030s, Saab is currently developing two uncrewed technology demonstrators, designated A1 and A2, under its Autonomous Collaborative Platform (ACP) roadmap. These initial demonstrators are funded by the Swedish Ministry of Defence.
Reporting by The War Zone indicates that the A1 demonstrator is expected to make its first flight within approximately 15 months. The A1 will be powered by a General Electric (GE) F414 engine, which is the same powerplant utilized in the Gripen E and F models.
“We are currently in an intensive development phase where, together with Sweden, we are exploring technologies that will lay the foundation for the next generation of combat air systems,” said Peter Nilsson, Head of Business Unit Advanced Programs at Saab AB. “As part of this work, we intend to fly uncrewed demonstrators with fighter-like characteristics before 2030 as we support Sweden in considering their future options.”
Strategic positioning and future combat systems
The A3-001 concept falls under Sweden’s broader Koncept för Framtida Stridsflygplan (KFS), or Concept for Future Combat Aircraft project. The War Zone notes that the A3-001 is positioned as a higher-end, larger, and faster platform compared to the Collaborative Combat Aircraft (CCA) currently under development for the United States Air Forces.
Saab intends for the A3-001 to leverage the company’s existing sensor and command infrastructure. Nilsson stated that the A3 system is a concept for what could follow the demonstrator phase should the Swedish government decide to proceed with development.
“Saab is well positioned to develop the next generation of combat air systems building on Gripen and GlobalEye, combined with our long experience in advanced aerospace systems,” Nilsson said.
AirPro News analysis
We view Saab’s decision to power the near-term A1 demonstrator with the GE F414 engine as a pragmatic approach to reducing developmental risk. By utilizing the same propulsion system as the Gripen E, Saab ensures immediate logistical and maintenance commonality, which is critical for testing manned-unmanned teaming concepts. It is necessary to distinguish between the funded A1 and A2 demonstrators and the A3-001 mock-up showcased on August 22, 2026. The A3-001 remains a company-funded concept illustrating potential future capabilities rather than an active acquisition program. Its realization will depend entirely on future procurement decisions by the Swedish Armed Forces following the data gathered from the A1 and A2 flight test campaigns.
Sources: Saab AB
Photo Credit: Saab AB
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