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