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Starfighters Space and GE Aerospace Complete Supersonic Ramjet Test Campaign

Starfighters Space and GE Aerospace concluded supersonic tests of a solid-fuel ramjet using F-104 aircraft at Kennedy Space Center, advancing hypersonic tech.

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Starfighters Space and GE Aerospace Complete Supersonic Ramjet Test Campaign

On January 5, 2026, Starfighters Space, Inc. (NYSE American: FJET) announced the successful conclusion of a supersonic flight test campaign conducted in collaboration with GE Aerospace. Operating from the Kennedy Space Center in Florida, the company utilized its fleet of F-104 Starfighter aircraft to execute high-speed “captive carry” missions for GE’s Atmospheric Test of Launched Air-breathing System (ATLAS).

According to the company’s official statement, the tests involved carrying the ATLAS test vehicle under the wing of the F-104 at speeds exceeding Mach 2. These flights were designed to validate critical performance metrics for GE’s solid-fuel ramjet (SFRJ) technology, a propulsion system intended for future hypersonic applications. The campaign was supported by funding from the U.S. Department of Defense under Title III of the Defense Production Act.

The collaboration highlights a growing trend in the aerospace sector where legacy platforms are repurposed to accelerate the development of next-generation defense technologies. By using a reusable, piloted aircraft, the program aimed to simulate realistic atmospheric conditions for the ramjet engine without the high costs associated with expendable rocket launches.

Technical Achievements and Flight Profile

The core objective of the campaign was to subject the ATLAS payload to the specific airflow and thermal environments required to “start” a ramjet engine. Unlike traditional jet engines that use rotating compressors, ramjets rely on the vehicle’s forward supersonic motion to compress incoming air. The F-104 Starfighter, capable of sustained Mach 2 flight, served as a “flying wind tunnel” for these tests.

The ATLAS Payload

GE Aerospace’s ATLAS vehicle utilizes a solid-fuel ramjet architecture. This design is distinct because it contains no moving parts and uses a solid hydrocarbon fuel lining the combustor. As the engine operates, the fuel ablates, or burns away, to sustain thrust. The technology is engineered to power vehicles at hypersonic speeds, generally defined as Mach 5 or higher.

In the press release, GE Aerospace executives noted the importance of real-world flight conditions for maturing this technology.

“The Starfighters team provided a reliable, flight-ready supersonic platform that enabled us to conduct multiple captive carry flights in realistic atmospheric conditions. Commercially operated test aircraft… play an important role in accelerating development timelines.”

Mark Rettig, VP & General Manager, Edison Works Business & Technology Development, GE Aerospace

Operational Context

Starfighters Space operates the world’s only commercial fleet of F-104s. These aircraft are certified to fly within designated supersonic corridors, such as the warning areas off the Florida coast. This capability allows defense primes and government agencies to gather data on ignition, combustion stability, and thrust in a high-cadence testing environment.

“For customers developing next-generation propulsion and aerospace systems, access to flight-proven supersonic platforms is essential. These missions not only validate our business model, but also demonstrate the advanced capabilities of our aircraft.”

Rick Svetkoff, CEO of Starfighters Space

Strategic Implications for Hypersonic Development

AirPro News analysis

The successful completion of the ATLAS campaign underscores a critical bottleneck in the United States’ pursuit of hypersonic capabilities: testing infrastructure. As the Department of Defense races to match the capabilities of near-peer competitors, the demand for wind tunnels and flight test opportunities has outstripped supply. Traditional testing methods often involve building expensive, single-use rocket boosters to accelerate test vehicles to the required speeds.

By utilizing the F-104 platform, Starfighters Space offers a solution that bridges the gap between ground-based wind tunnels and full-scale rocket launches. This approach aligns with the broader industry push toward “responsive space” and rapid prototyping. The use of Defense Production Act Title III funding for this program further signals the Pentagon’s intent to shore up the domestic industrial base for high-speed Propulsion.

While other companies like Stratolaunch and Hermeus are developing new platforms for similar purposes, Starfighters Space leverages a legacy platform that is already certified and operational. This allows for immediate testing capabilities, a crucial factor as the U.S. government seeks to deploy hypersonic systems in the near term.

Frequently Asked Questions

What is a Solid-Fuel Ramjet (SFRJ)?

A solid-fuel ramjet is a type of jet engine that uses the vehicle’s forward motion to compress air, which is then mixed with a solid fuel source lining the combustion chamber. It has no moving parts, making it simpler and potentially more robust than liquid-fuel engines for certain high-speed applications.

Why use an F-104 Starfighter for testing?

The F-104 is one of the few aircraft capable of sustained flight at Mach 2 (twice the speed of sound) while carrying heavy external payloads. Its high speed allows it to simulate the airflow conditions necessary to ignite and test ramjet engines, acting effectively as a reusable first stage or a flying testbed.

What is the significance of the Defense Production Act Title III funding?

Title III of the Defense Production Act provides the President with the authority to ensure the domestic industry can meet national defense needs. Funding under this title indicates that the technology being tested, in this case, solid-fuel ramjets, is considered essential to national security.

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Photo Credit: Starfighters Space

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Defense & Military

Hungary Expands Gripen Fleet with Two New Saab Fighter Jets

Hungary receives two new Saab Gripen fighters, expanding its fleet to 18 and upgrading to the MS20 Block 2 standard for enhanced NATO capabilities.

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This article is based on an official press release from Saab.

Hungary Expands Air Force Fleet with Two New Saab Gripen Fighters

On April 30, 2026, the Hungarian Defence Forces officially took delivery of two new Saab JAS 39 Gripen C fighter jets. According to an official press release from Saab, this delivery marks the first half of a four-aircraft expansion order that will increase Hungary’s total Gripen fleet from 14 to 18 aircraft. The arrival of these jets represents a significant milestone in the nation’s ongoing military modernization efforts.

Hungary has operated the Swedish-built multirole fighters since 2006, initially leasing 12 single-seat JAS 39C and two two-seat JAS 39D variants to replace its aging Soviet-era MiG-29 fleet. The year 2026 serves as a major transition period for the Hungarian Air-Forces, as ownership of the original 14 leased aircraft will officially transfer from the Swedish Defence Materiel Administration (FMV) to the Hungarian government.

We note that this fleet expansion is part of a broader strategy to bolster national and regional air defense capabilities amidst a shifting European security landscape. The new aircraft will be stationed at Kecskemét Air Base in central Hungary, operated by the 101st Aviation Wing.

Fleet Expansion and Modernization Timeline

Transitioning to the MS20 Block 2 Standard

The procurement of the four additional Gripen C fighters stems from a contract amendment signed between the Hungarian Ministry of Defence and the FMV on February 23, 2024. Saab has maintained a strict production schedule for this order. Highlighting the delivery schedule, industry research reports state:

The deliveries confirms Saab’s commitment to its production timeline, with the final two aircraft of the four-jet order expected to arrive by June 30, 2026.

Beyond the acquisition of new airframes, Hungary’s entire Gripen fleet is undergoing a comprehensive modernization process. According to a separate contract signed with Saab in August 2021, the aircraft are being upgraded to the advanced MS20 Block 2 standard. This upgrade significantly enhances the fleet’s combat capabilities and ensures seamless interoperability with NATO forces.

The MS20 Block 2 modernization includes the installation of the advanced PS-05/A Mk4 radar-systems, which improves tracking range and performance against low-trajectory targets and electronic jamming. Furthermore, the upgrade integrates improved NATO Link 16 connectivity and Mode 5 Identification Friend or Foe (IFF) capabilities. This technological leap allows the Hungarian Air Force to deploy a wider array of modern weaponry, including the IRIS-T short-range air-to-air missile, GBU-49 laser-guided bombs, and the Meteor beyond-visual-range missile.

Strategic Implications for Central European Defense

NATO Commitments and Regional Security

The expanded and upgraded Gripen fleet forms the backbone of Hungary’s national defense and its international NATO commitments. Hungarian JAS-39 aircraft are regular participants in NATO’s Baltic Air Policing (BAP) missions. In September 2025, Hungarian Gripens successfully intercepted Russian military aircraft flying over the Baltic Sea without filed flight plans or radio communications, demonstrating the fleet’s operational readiness.

Beyond its own borders, Hungary leverages its Gripen fleet to provide regional security. The Hungarian Air Force jointly safeguards Slovenia’s airspace alongside Italy and contributes to the air defense of Slovakia in cooperation with the Visegrád Group (V4). Expanding the fleet to 18 aircraft allows for higher sortie rates, dispersed operations, and continuous air policing coverage across Central Europe.

Deepening Industrial Ties Between Saab and Hungary

Aviation Development and Virtual Reality

The relationship between Hungary and Saab extends significantly beyond military procurement, evolving into a strategic industrial partnerships. According to the company’s announcements, Saab is deepening its ties with Hungary through targeted investments in high-tech sectors.

Lars Tossman, head of Saab’s Aeronautics business area, has highlighted the company’s preparedness to invest in an Aviation Development Centre in Hungary. This initiative will allow the Hungarian defense sector to influence and benefit directly from the continuous development of the Gripen system. Additionally, Saab and the Hungarian Ministry of Defence have signed a Memorandum of Understanding (MoU) to support the establishment of a Centre of Excellence for Virtual Reality (VR) technologies within the country.

AirPro News analysis

We view the 2026 transition from a lease model to full ownership as a pivotal moment for the Hungarian Defence Forces. By securing full ownership of the original 14 airframes and expanding the fleet to 18, Hungary is cementing its long-term commitment to the Gripen ecosystem. Furthermore, the accompanying long-term maintenance agreement with Saab, which extends to at least 2036, provides Hungary with critical cost predictability and guarantees high operational readiness for the next decade. The concurrent investments in local VR and aviation development centers suggest that Saab is successfully using industrial offsets to secure its footprint in Central Europe against competing fighter platforms.

Frequently Asked Questions

When will the remaining Gripen fighters be delivered to Hungary?
According to current production timelines, the final two aircraft of the four-jet order are expected to arrive by June 30, 2026.

What upgrades are included in the MS20 Block 2 standard?
The upgrade includes the advanced PS-05/A Mk4 radar, improved NATO Link 16 connectivity, Mode 5 IFF capability, and integration for modern weapons such as the IRIS-T, GBU-49, and Meteor missiles.

Where are the Hungarian Gripen fighters based?
The fleet is operated by the 101st Aviation Wing, stationed at Kecskemét Air Base in central Hungary.


Sources:

Photo Credit: SAAB

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Lockheed Martin Advances Laser Powder-Bed Fusion Additive Manufacturing

Lockheed Martin enhances LPBF additive manufacturing to improve aerospace thermal management and supply chain resilience, deploying tech on key defense platforms.

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This article is based on an official press release from Lockheed Martin.

Lockheed Martin Accelerates Operational Readiness with Advanced LPBF Additive Manufacturing

On April 30, 2026, Lockheed Martin announced significant advancements in its Laser Powder-Bed Fusion (LPBF) additive manufacturing capabilities. According to the company’s official press release, this initiative is designed to drive supply chain resilience, accelerate design-to-flight timelines, and enable faster operational readiness for next-generation military-aircraft, hypersonic systems, and electric propulsion platforms.

By partnering with specialized technology firms, the defense contractor has successfully optimized the production of complex thermal management components. We note that these advancements allow for lighter, more efficient parts that bypass traditional manufacturing bottlenecks, directly supporting longer mission endurance and lower lifecycle costs for aerospace and defense applications.

Overcoming Thermal Management and Supply Chain Bottlenecks

The Shift from Traditional Manufacturing

High-performance electronics and propulsion systems, particularly those used in modern aerospace and hypersonic applications, generate extreme heat. Historically, regulating these temperatures required highly complex thermal management systems built through traditional casting, forging, and brazing. As detailed in the provided research, these legacy methods demand costly metal fabrication and strict aerospace-grade tolerances, often resulting in major supply chain choke points due to raw-material lead times, alloy shortages, and geopolitical disruptions.

Lockheed Martin’s LPBF additive manufacturing addresses these challenges by utilizing design-driven digital processes to build metal parts layer-by-layer from metal powder. The company states that this approach eliminates the need for expensive, time-intensive hard tooling, allowing components to be manufactured with high precision in smaller quantities and drastically shortening development cycles.

Strategic Partnerships and Measurable Performance Gains

Building an End-to-End Ecosystem

To achieve these manufacturing breakthroughs, Lockheed Martin collaborated with key industry partners, including Sintavia, EOS, Nikon SLM, and nTop. Through the integration of generative design software from nTop, the company optimized part geometries for maximum heat dissipation and minimum weight. Furthermore, collaborations with EOS and Sintavia led to a co-developed LPBF processing window and bespoke tool path strategies that push the limits of feature resolution.

According to the release, these optimized processes have yielded a 15% to 20% reduction in overall system weight and boosted heat dissipation efficiency by 10% to 15%. The new workflow also integrates third-party sensor systems and AI-enabled analysis for real-time melt pool monitoring. This allows the system to detect defects early and automatically flag suspect zones, enabling tighter assembly tolerances and significantly reducing post-processing inspection workloads.

These improvements are already actively powering key warfighter platforms. Lockheed Martin confirmed that the LPBF technology is currently deployed on the UH-60M BlackHawk helicopter and the Precision Strike Missile (PrSM).

“Combining our LPBF expertise with the specialized capabilities of our partners, Sintavia, EOS, Nikon SLM, and nTop, has created an end-to-end ecosystem that accelerates design to flight timelines without compromising reliability,” said David Tatro, Vice President of Operations Technology at Lockheed Martin. “This collaborative approach positions us to meet the escalating thermal management demands of next generation aircraft, hypersonic systems and electric propulsion platforms ensuring they meet rigorous certification standards and achieve operational readiness.”

Broader Additive Manufacturing Strategy

Expanding Facilities and International Interoperability

Lockheed Martin’s April 2026 announcement builds upon a sustained, multi-year investment in 3D printing technologies. In 2024, the company’s Missiles and Fire Control facility in Grand Prairie, Texas, opened a 16,000-square-foot additive manufacturing space housing some of the largest-format, multi-laser machines in the state.

Additionally, in January 2026, Lockheed Martin was selected to lead a project for America Makes’ Allied Additive Manufacturing Interoperability (AAMI) Program. Backed by the U.S. Department of Defense, this initiative aims to establish an interoperable LPBF supply chain framework between the U.S. DoD and the U.K. Ministry of Defense. The company is also actively working with the DoD’s LIFT Institute and 3D printing firm Velo3D to certify materials for additively manufactured aerospace systems, specifically focusing on 3D-printed ramjet engines capable of surviving hypersonic flight above Mach 5.

“We continue to invest in AM technology to provide value for our customers in a way that empowers our engineers to innovate and rapidly integrate new product designs and capabilities to the production floor,” stated Tom Carrubba, Vice President of Production Operations at Lockheed Martin Missiles and Fire Control, in earlier 2026 remarks regarding the company’s broader strategy. “This allows us to create affordable and modular designs that can simplify both high and low-volume production processes.”

AirPro News analysis

We observe that Lockheed Martin’s aggressive expansion into LPBF additive manufacturing signals a critical pivot in defense industrial strategy. By transitioning 3D printing from a rapid-prototyping novelty to a core production methodology, major defense contractors are actively insulating themselves against fragile global supply chains. The integration of AI-driven quality control and real-time defect detection is particularly noteworthy, as it directly addresses the historical hurdle of achieving strict aerospace-grade certification for additively manufactured parts.

Frequently Asked Questions (FAQ)

  • What is LPBF?
    Laser Powder-Bed Fusion (LPBF) is an additive manufacturing (3D printing) process that uses lasers to melt and fuse metallic powder together layer-by-layer to create highly complex, precision parts without the need for traditional hard tooling.
  • What are the performance benefits of Lockheed Martin’s new LPBF process?
    The optimized process has achieved a 15% to 20% reduction in overall system weight and a 10% to 15% boost in heat dissipation efficiency.
  • Which platforms are currently using this technology?
    Lockheed Martin has already deployed LPBF-manufactured components on the UH-60M BlackHawk helicopter and the Precision Strike Missile (PrSM).

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Photo Credit: Lockheed Martin

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Defense & Military

US Navy Fleet Readiness Center East Delivers First Metal 3D-Printed Parts

The US Navy’s Fleet Readiness Center East delivers first flight-certified metal 3D-printed parts, reducing aircraft downtime and expanding capabilities.

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This article is based on an official press release from the United States Navy.

The United States Navy’s Fleet Readiness Center East (FRCE) has officially entered a new era of aircraft sustainment, delivering its first flight-certified metal 3D-printed parts to the fleet. According to an official press release, this milestone is expected to significantly reduce aircraft downtime and improve flight line readiness for critical Military-Aircraft assets.

The achievement stems from a collaboration between the FRCE’s Advanced Technology and Innovation Team, the Naval Air Systems Command (NAVAIR) Additive Manufacturing Team, and various Fleet Support Teams. By leveraging metal additive manufacturing, the depot has successfully developed processes and obtained certifications to produce non-flight-critical aircraft components on demand.

We recognize this development as a major step forward in military logistics. By producing parts locally and rapidly, the Navy can bypass traditional supply chain bottlenecks, ensuring that aircraft remain operational when they are needed most.

First Flight-Worthy Deliveries

Unlike traditional 3D printing that uses plastic filament, the FRCE’s metal additive manufacturing process utilizes high-powered lasers to weld thin layers of aluminum powder into solid objects. The official release notes that since establishing this capability, the facility has manufactured and delivered three specific flight-worthy parts to the fleet.

The first of these components was a weapons pylon fitting for the AH-1Z Viper, which was delivered to the H-1 Fleet Support Team in early 2025. Later that year, the depot supplied a repair fitting for the main landing gear of the V-22 Osprey, as well as a blanking plate for the C-130 Hercules.

Rapid Certification and Production

Beyond the physical deliveries, the FRCE achieved a significant administrative and operational milestone by completing a rigorous capability demonstration in under six months. This rapid turnaround serves as formal validation that the 3D-printed metal parts meet the same stringent safety and quality requirements as traditionally manufactured components.

“We were challenged to complete the qualification, production and certification processes for these parts in six months, and we not only met but exceeded that standard,” stated the FRCE’s Advanced Technology and Innovation Team lead in the press release. “This is the fastest this sort of thing has ever been done within Naval Air Systems Command, and it shows that we are competitive with industry standards.”

Overcoming Supply-Chain Hurdles

The integration of metal additive manufacturing represents a strategic shift in how the military supports its warfighters. By producing parts in-house, the Navy can provide a time-saving solution for replacing worn or damaged components that are often difficult to source through traditional procurement channels.

For example, the V-22 Osprey fleet had been experiencing difficulties obtaining repair fittings for its main landing gear. According to the Navy’s statement, the fleet turned to the additive manufacturing team to solve this shortage, resulting in the successful production of the needed parts during the capability demonstration phase.

Future Expansion into Stainless Steel

Looking ahead, the FRCE plans to expand its additive manufacturing capabilities beyond aluminum. The press release indicates that the facility will soon begin working with stainless steel, a material that offers greater strength and durability. This expansion will enable the depot to produce a wider array of flight-critical parts and support equipment.

In addition to aircraft components, the FRCE is already utilizing its 3D printing equipment to create specialized tooling and support parts for its own maintainers, streamlining the repair process across the board.

AirPro News analysis

We view the FRCE’s rapid adoption of metal additive manufacturing as a critical indicator of broader trends in aerospace and defense logistics. The ability to certify and produce metal parts in under six months demonstrates a significant maturation of 3D printing technologies within highly regulated environments. As the FRCE, North-America‘s largest maintenance, repair, and overhaul provider with over 4,000 workers and $865 million in annual revenue, expands into stainless steel, we anticipate a cascading effect where localized, on-demand manufacturing becomes the standard rather than the exception for military sustainment.

Frequently Asked Questions

What is metal additive manufacturing?

Metal additive manufacturing is a 3D printing process that uses high-powered lasers to weld thin layers of metal powder (such as aluminum or stainless steel) into a solid, functional object.

Which aircraft received the first 3D-printed parts from FRCE?

According to the Navy’s press release, the first parts were delivered for the AH-1Z Viper, the V-22 Osprey, and the C-130 Hercules.

How long did the certification process take?

The FRCE completed the rigorous capability demonstration and Certification process in under six months, marking the fastest timeline for this type of achievement within the Naval Air Systems Command.

Sources

Photo Credit: United States Navy

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