Aurora Flight Sciences Advances X-65 with Active Flow Control Technology

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