World’s first software-defined fuselage to boost fighter jet agility

Swedish aerospace company Saab, in partnership with Divergent Technologies, has developed the world’s first software-defined aircraft fuselage, marking a significant advancement in fighter jet design and manufacturing. This experimental fuselage, over five meters long and composed of 26 unique 3D-printed metal parts, was produced using large-scale metal additive manufacturing combined with software-driven production techniques. Notably, no traditional tooling or fixtures were needed, making it one of the largest additively manufactured metal structures prepared for powered flight. Having passed structural proof-loading tests, the fuselage is slated for flight testing in 2026. This innovation aligns with Saab’s strategic move toward model-based engineering (MBE), which uses shared digital twins and 3D digital instructions to streamline design, simulation, and system optimization, as demonstrated in the Gripen E fighter program. Saab’s internal innovation team, The Rainforest, is pushing the concept further by exploring “Software-Defined Hardware Manufacturing,” aiming to bring the same software