Articles tagged with "aerospace-materials"
Renault to build long‑range surveillance and strike drones for France
French automaker Renault has announced a partnership with defense contractor Turgis Gaillard to manufacture long-range strike drones for France under a potential €1 billion (US$1.2 billion) contract with the Directorate General for Armament. These drones, resembling Iran’s low-cost Shahed loitering munitions, will be produced at Renault’s Le Mans and Cléon facilities, with chassis and engines respectively. The drones are expected to have a 10-meter wingspan and be offered at a highly competitive price. Renault’s chief growth officer, Fabrice Cambolive, confirmed the company was approached by the French Ministry of the Armed Forces to leverage its industrial and design expertise for this defense project. The drones will be remotely operated and designed for surveillance, reconnaissance, and combat roles, similar to the Iranian Shahed drones that have been reverse-engineered by the US and used extensively in conflicts such as in Ukraine. This initiative aligns with French President Emmanuel Macron’s recent calls for the defense industry to
robotdronesdefense-technologysurveillanceautonomous-systemsmanufacturingaerospace-materialsNext-gen ‘Space Armor’ tiles to launch on SpaceX mission for next-gen debris defense
Atomic-6, a company specializing in advanced composite materials, is set to test its innovative Space Armor shield material in orbit for the first time through a collaboration with aerospace defense startup Portal Space Systems. The Space Armor tiles, designed as a lightweight and thin alternative to traditional metallic Whipple shields, will be installed on Portal’s Supernova spacecraft, which is scheduled to launch aboard SpaceX’s Transporter-18 rideshare mission in October 2026. Unlike Whipple shields that fragment debris upon impact, Space Armor absorbs and contains impacts, reducing secondary debris and enhancing spacecraft protection. The upcoming in-orbit test aims to validate installation procedures, on-orbit performance, and readiness for broader commercial and national security use. Space Armor’s hexagonal tiles, about three-quarters of an inch thick, have already passed successful hypervelocity impact tests simulating space debris collisions at speeds over 7 kilometers per second. Portal’s CEO, Jeff Thornburg, emphasized that Space Armor will enable their spacecraft to maintain sustained maneuver
materialscomposite-materialsspace-armororbital-debris-protectionspacecraft-shieldingaerospace-materialsmicrometeoroid-protectionIndian SpaceX rival EtherealX hits 5x valuation as it readies engine tests
Ethereal Exploration Guild (EtherealX), an Indian space technology startup, has seen its valuation surge 5.5 times to $80.5 million following a $20.5 million oversubscribed Series A funding round led by TDK Ventures and BIG Capital. The Bengaluru-based company is developing a fully reusable launch vehicle designed to return both the booster and upper stage, aiming to reduce launch costs and increase flight frequency. EtherealX plans to conduct hot-fire tests of its two in-house developed engines—the 80-kilonewton Pegasus upper-stage engine and the 1.2-meganewton Stallion booster engine—in June–July 2026, with a technology demonstration flight targeted for late 2027 and commercial missions expected by the end of 2028. The startup’s medium-lift vehicle, Razor Crest Mk-1, will cluster multiple engines per stage (nine Stallion engines on the booster and 15 Pegasus engines on the upper stage) and aims
energyrocket-enginesspace-technologyreusable-launch-vehicleadditive-manufacturingpropulsion-systemsaerospace-materials1,000 times self-healing tech could extend aircraft life by centuries
Researchers at North Carolina State University have developed a novel self-healing composite material capable of repairing itself over 1,000 times, potentially extending the lifespan of critical infrastructure from decades to centuries. This innovation targets the longstanding issue of interlaminar delamination—a form of internal cracking that has limited the durability of fiber-reinforced polymer (FRP) composites used in aircraft, automobiles, wind turbines, and spacecraft. By integrating a 3D-printed thermoplastic healing agent and embedded carbon-based heater layers into conventional FRPs, the material becomes two to four times more resistant to delamination and can self-repair cracks when electrically heated, restoring its structural integrity. The composite was rigorously tested through 1,000 cycles of induced fractures followed by thermal healing over 40 days, demonstrating sustained fracture resistance well above that of unmodified composites. Although some gradual decline in healing efficiency occurs due to microscopic fiber wear and chemical changes, statistical modeling indicates the material remains structurally viable for centuries. This technology
materialsself-healing-materialscomposite-materialsfiber-reinforced-polymersaerospace-materials3D-printingcarbon-fiber-compositesNew nature-inspired metal could enable morphing aircraft wings
Researchers at Nanjing University of Aeronautics and Astronautics (NUAA) have developed a novel nature-inspired metal metamaterial designed to enable shape-shifting aircraft wings. Unlike previous materials that were either too weak or mechanically cumbersome, this new alloy is lightweight, durable, and flexible, capable of smoothly changing shape during flight and autonomously recovering its original form. The material is based on a nickel-titanium shape memory alloy fabricated using laser powder bed fusion (LPBF), a precise metal 3D printing technique that allowed the creation of tiny wavy structural features mimicking the seedcoat of the succulent plant Portulaca oleracea. This biomimicry resulted in a metal network honeycomb structure that can stretch up to 38% before fracturing and recover over 96% of its programmed shape when heated. The NUAA team demonstrated the material’s potential by building prototype wing sections that could morph smoothly between angles of −25° to 25° under low temperatures similar
materialsmetamaterialsshape-memory-alloyaerospace-materials3D-printingmorphing-aircraftnickel-titanium-alloyChina launches two experimental target detection satellites to orbit
China successfully launched two experimental satellites, Shijian 29A and 29B, on December 31, 2025, using a Long March 7A rocket from the Wenchang Space Launch Center. These satellites are part of a technology demonstration mission to test new space-based target detection technologies. The launch marked China’s 92nd orbital mission of 2025 and the 623rd flight of the Long March rocket family, underscoring a record year for the nation’s space program. Shijian 29A was developed by the Shanghai Academy of Spaceflight Technology, while Shijian 29B was built by the Innovation Academy for Microsatellites, both subsidiaries of major Chinese aerospace organizations. The Shijian satellite series has a history of testing advanced space capabilities, including on-orbit refueling and towing maneuvers, as demonstrated by earlier satellites Shijian 21 and 25. Although China’s space administration remains secretive about the specifics of Sh
satellitesspace-technologytarget-detectionLong-March-rocketon-orbit-refuelingspace-innovationaerospace-materialsB-2 bombers' biggest opponent: Rain used to erode plane's stealthiness
The B-2 stealth bomber, despite its advanced design and high cost, has long faced significant challenges related to its radar-evading coatings and sensitivity to rain and moisture. Reports and a U.S. General Accounting Office (GAO) study revealed that exposure to water and humidity damages the aircraft’s low-observable materials, causing water to accumulate in compartments, ducts, and valves, which can lead to system malfunctions. This vulnerability contributed to the 2008 crash of a B-2, known as The Spirit of Kansas, where moisture in the aircraft’s sensors distorted air data during takeoff. The bomber’s coatings require frequent, lengthy maintenance—accounting for nearly 39% of maintenance man-hours per flight hour—and necessitate environmentally controlled shelters, making it impractical to deploy the B-2 without protective hangars. Operational testing showed that the B-2’s mission-capable rate significantly decreases when low-observability issues are factored in, dropping from 66% to
materialsstealth-technologyaircraft-coatingserosion-resistancemaintenance-challengeslow-observable-materialsaerospace-materialsPhotos: Alien-like drone ‘rains’ chilled beers from sky using mini parachutes
The Stratos MK1 is a conceptual drone designed specifically for aerial beverage delivery, featuring a unique spider-like frame made from carbon fiber and aerospace-grade materials. It can carry up to eight individual beer cans in a central keg-shaped compartment, releasing them one at a time using small parachutes that deploy based on calculated altitude and wind conditions to ensure safe landings. The drone’s autonomous navigation is managed by internal sensors and mapping software, enabling obstacle avoidance and precise delivery to GPS-specified locations. An integrated mobile app allows users to place orders, track the drone in real time, and receive proximity alerts. In addition to individual cans, the MK1 can transport a 5-liter mini keg, which it lands with directly rather than dropping by parachute. The drone’s folding propeller arms provide stability on uneven surfaces during keg delivery. The keg itself is made of stainless steel with reinforced brackets and an internal pump for dispensing. To maintain beverage temperature during flight, the drone includes an internal cooling system within the
robotdrone-technologyautonomous-systemsIoTaerospace-materialsdelivery-dronescooling-systemsUS awards $3.5 billion for satellites to track hypersonic missiles
The U.S. Space Development Agency (SDA) has awarded approximately $3.5 billion in contracts to four companies—L3Harris Technologies, Lockheed Martin, Rocket Lab USA, and Northrop Grumman—to build 72 missile-tracking satellites for the Tracking Layer Tranche 3 segment of the Proliferated Warfighter Space Architecture (PWSA). These satellites, scheduled for launch in fiscal year 2029, will enhance low Earth orbit (LEO) coverage to detect and track advanced missile threats, including hypersonic missiles traveling at speeds of Mach 5 or higher. Each satellite will be equipped with infrared sensors, optical communications terminals, Ka-band payloads, and an S-band backup system to ensure robust missile tracking capabilities. The constellation will be deployed across eight orbital planes and integrated with SDA’s Transport Layer, a mesh network designed to rapidly relay data to missile defense systems. This integration aims to provide near-continuous global coverage and improve the speed and
IoTsatellite-technologymissile-trackinghypersonic-missilesspace-defensecommunication-systemsaerospace-materials3D-printed aluminum that withstands 572°F could reshape engine design
Researchers at Nagoya University have developed a new class of 3D-printed aluminum alloys that defy traditional metallurgical rules by incorporating iron—previously considered a contaminant that weakens aluminum—alongside manganese and titanium. Using laser powder bed fusion 3D printing, which rapidly cools molten metal layers, the team created alloys with unique micro- and nano-structures that prevent the brittleness and corrosion typically caused by iron. This rapid solidification enables the formation of metastable phases that enhance both strength and heat resistance, allowing one alloy variant to maintain flexibility and strength at temperatures up to 300°C (572°F). The breakthrough alloy (Al-Fe-Mn-Ti) not only achieves high strength at room temperature but also sustains exceptional mechanical properties at elevated temperatures, making it ideal for demanding automotive and aerospace applications such as engines and turbines. The materials are composed of low-cost, abundant elements and are designed to be recyclable, addressing sustainability concerns. Additionally, these alloys are easier
materials3D-printingaluminum-alloysheat-resistant-materialsautomotive-materialsaerospace-materialsmetal-alloysNorthrop reveals lightweight combat drone to flank US Air Force jets
Northrop Grumman has introduced Project Talon, a new lightweight autonomous combat drone designed to support US Air Force jets by providing affordable, high-performance capabilities. Unveiled on December 3 at Northrop’s Scaled Composites facility in Mojave, California, Project Talon aims to address shortcomings in Northrop’s earlier Collaborative Combat Aircraft (CCA) proposal, which performed well but was too costly. The drone is about 1,000 pounds lighter than the previous design, features a fully composite structure, and has 50% fewer parts, enabling a 30% reduction in production time. Northrop emphasizes that the key innovation lies not just in the aircraft itself but in a streamlined development process that integrates design and manufacturing teams to accelerate production and reduce costs. Project Talon is expected to fly for the first time by fall 2026 and surpasses Northrop’s internal affordability and performance targets, although detailed specifications remain undisclosed. The drone fits into the Air Force’s vision of
robotautonomous-dronescombat-droneaerospace-materialslightweight-composite-structuresmilitary-technologydrone-manufacturingChina's stealth jet coating reduces radar signal intensity by 700x
Chinese researchers from the People’s Liberation Army and China Aerospace Science and Industry Corporation have developed an ultra-thin stealth coating derived from loofah to significantly reduce radar signal detection of fighter jets. By carbonizing dried loofah and embedding it with nickel cobalt oxide (NiCo₂O₄) magnetic nanoparticles, the resulting composite, named NCO-2, absorbs over 99.99% of incident electromagnetic waves in the Ku-band frequency range (12-18 GHz). At just 4mm thick, this coating can reduce reflected radar signal intensity by nearly 700 times, effectively shrinking a stealth aircraft’s radar cross-section from 50 square meters to less than 1 square meter, even when radar beams come from directly above. The coating’s effectiveness is attributed to the loofah’s natural 3D network of cellulose fibers, which, when carbonized, form a lightweight conductive scaffold with mazelike pores. Electromagnetic waves entering this structure undergo multiple internal reflections, increasing absorption
materialsstealth-technologyelectromagnetic-wave-absorptioncarbon-compositeradar-stealthnanomaterialsaerospace-materialsUkraine destroys Russia's test aircraft for airborne laser weapons
A recent Ukrainian strike on the Beriev aircraft manufacturing facility in Taganrog, southwestern Russia, destroyed a rare and significant Russian military asset: the A-60 airborne laser test aircraft. The A-60, a unique Soviet-era platform built from an Il-76MD transport jet, was Russia’s only flying testbed for airborne laser weapons. Satellite imagery confirmed the aircraft was engulfed in flames and severely damaged, marking a major setback for Russia’s laser weapons program, whose current status was already uncertain. Alongside the A-60, another advanced aircraft, likely a testbed for the A-100 airborne early warning and control (AEW&C) system, was also destroyed. Ukraine’s Ministry of Defense reported using a combination of Bars long-range jet-powered attack drones and Neptune land-attack cruise missiles to carry out the strike. The Neptune missile, originally an anti-ship weapon, has been adapted for deep strikes into Russian territory, while the Bars drone represents Ukraine’s growing long-range strike capabilities
energylaser-weaponsmilitary-aviationairborne-laserdrone-technologymissile-technologyaerospace-materialsLight, extremely strong material withstands 932°F temperature, could be useful for aerospace
Researchers at the University of Toronto Engineering have developed a novel lightweight and extremely strong metal matrix composite capable of withstanding temperatures up to 932°F (500°C), making it highly promising for aerospace and other high-performance applications. The material mimics the structure of reinforced concrete on a microscopic scale, featuring a titanium alloy mesh acting as "rebar" surrounded by a matrix composed of aluminum, silicon, magnesium, and embedded alumina and silicon nanoprecipitates. This design, enabled by additive manufacturing and micro-casting techniques, allows precise control over the composite’s microstructure, resulting in exceptional strength and thermal resistance. Testing revealed that the composite exhibits a yield strength of around 700 megapascals at room temperature—significantly higher than typical aluminum matrices—and maintains 300 to 400 megapascals at 500°C, compared to just 5 megapascals for conventional aluminum alloys. This performance rivals medium-range steels but at roughly one-third the weight, addressing a critical limitation of aluminum alloys
materialscomposite-materialsaerospace-materialsmetal-matrix-compositeadditive-manufacturinghigh-temperature-materialslightweight-materialsNew US heatshield tech to guard nuclear missiles at Mach 5 speeds
The US Navy has awarded TexTech Engineered Composites a $76.8 million contract to supply advanced carbon-phenolic heatshield materials and other reentry components for American and British strategic missile programs, primarily supporting submarine-launched ballistic missile (SLBM) reentry vehicles. This cost-plus-fixed-fee, indefinite-delivery/indefinite-quantity contract extends through October 2030 and includes both production and research and development efforts to advance next-generation thermal-protection systems. The contract reflects the US-UK partnership in the Trident missile program, with the UK accounting for 2% of the purchases under the Foreign Military Sales program. Work will be performed in Winston-Salem, North Carolina, and the contract was awarded on a sole-source basis due to TexTech’s unique capability to produce these specialized carbon-phenolic composites. Carbon-phenolic materials are critical for missile reentry vehicles, as they must withstand temperatures exceeding 5,000 degrees Fahrenheit during hypersonic atmospheric
materialscarbon-phenolic-compositesthermal-protection-systemsmissile-heatshieldadvanced-materialshypersonic-reentryaerospace-materialsChina’s first 3D-printed mini turbojet engine hits Mach 0.75 in tests
China’s state-owned Aero Engine Corporation of China (AECC) has successfully tested its first fully 3D-printed miniature turbojet engine in a solo flight, marking a significant milestone in the country’s independent aviation propulsion development. The ultra-lightweight engine, producing 353 pounds of thrust, powered a target drone to an altitude of 6,000 meters (about 20,000 feet) and reached speeds of Mach 0.75 during a 30-minute flight. The engine operated stably throughout, validating its design, reliability at higher altitudes, and integration with aircraft systems. This test follows an earlier captive-carry flight at 4,000 meters and represents a transition from controlled testing to operational application. The engine’s design leverages a combination of 3D printing and multi-disciplinary topology optimization (TO), a computational method that optimizes material distribution for performance and weight reduction. This approach enables the creation of complex, lightweight structures that traditional manufacturing cannot easily produce. Over three-
3D-printingadditive-manufacturingturbojet-engineaerospace-materialstopology-optimizationlightweight-materialsaviation-technologyGerman students build cargo bikes from aircraft parts for flood victims
Students from Chemnitz University of Technology in Germany collaborated with UK bicycle brand Vielo to build four ultra-light cargo bikes from recycled Airbus aircraft parts to aid flood victims in Spain’s Valencia region. The bikes, made from carbon-fiber tubes originally used in Airbus A380 aircraft and supplied by Elbe Flugzeugwerke GmbH, weigh just 28 lbs (13 kg) but can carry loads over 154 lbs (70 kg). These purpose-built cargo bikes were shipped to two of the hardest-hit towns in Valencia to help restore mobility following the devastating 2024 floods that caused at least 224 deaths. The project provided students with hands-on experience in sustainable materials use, lightweight construction, and prototype development, including CAD design, carbon winding, and epoxy bonding techniques. Despite challenges such as carbon discoloration after curing, the team successfully produced high-strength frames with a professional-grade strength-to-weight ratio. The humanitarian effort was coordinated by Vielo athlete Juan Dual, who led volunteer aid deliveries, while Vielo
materialscarbon-fiberrecyclinglightweight-constructionsustainable-materialsprototype-developmentaerospace-materialsChina claims new jet coating can survive 1,800°F and block radar
Chinese researchers from Peking University and Harbin Engineering University have developed an ultra-thin, heat-resistant coating designed to enhance stealth capabilities of fighter jets by absorbing radar waves. This metasurface coating, only 0.1 millimeters thick, can withstand extreme temperatures up to 1,832°F (1,000°C) and maintain its radar-absorbing properties under high-speed airflow conditions typical of supersonic flight. Created by depositing graphene onto a silica fabric substrate and then patterning it with lasers, the resulting graphene-silica fiber membrane is lightweight, flexible, and durable, capable of reducing radar reflection by up to -42 decibels without adding significant weight or altering aircraft structure. The technology represents a significant advancement in stealth materials, potentially applicable not only to military aircraft like China’s J-20 stealth fighter but also to satellites, drones, and hypersonic vehicles exposed to harsh thermal and electromagnetic environments. This innovation contrasts with current U.S. stealth coatings, which are fragile,
materialsadvanced-coatingsgraphenestealth-technologyelectromagnetic-absorptionthermal-stabilityaerospace-materialsChina's reusable rocket near launch after successful static fire test
China’s private space company LandSpace has successfully completed a critical static fire test of its Zhuque-3 rocket, bringing it closer to launching the nation’s first reusable rocket. The test, conducted on October 20, 2025, at the Dongfeng Commercial Space Innovation Pilot Zone, involved firing the rocket’s nine methane-liquid oxygen Tianque-12A engines while anchored to the ground. This milestone is part of the initial phase of the Zhuque-3’s maiden flight campaign, which also included a fueling test. Following this, the rocket will undergo vertical integration rehearsal and technical inspections before its planned orbital launch and first-stage recovery, expected before the end of the year. Zhuque-3 is a 66-meter tall, two-stage launch vehicle with a reusable first stage and an expendable upper stage, capable of lifting approximately 18,300 kg to low Earth orbit—slightly less than SpaceX’s Falcon 9. Its design closely mirrors Falcon 9, including the use
energyreusable-rocketrocket-enginespace-technologymethane-fuelliquid-oxygenaerospace-materialsIndia’s Airbound bags $8.65M to build rocket-like drones for one-cent deliveries
Airbound, an Indian drone startup founded in 2020 by then-15-year-old Naman Pushp, has raised $8.65 million in seed funding led by Lachy Groom, co-founder of Physical Intelligence. The funding round also included Humba Ventures, Lightspeed Venture Partners, and senior leaders from Tesla, SpaceX, and Anduril. Airbound is developing an ultra-light, rocket-like drone with a blended-wing-body design and carbon fiber frame, aiming to drastically reduce delivery costs. Unlike typical quadcopters, their tail-sitter drone takes off vertically like a rocket and flies efficiently like a plane, targeting delivery costs as low as one cent by improving aerodynamic efficiency and reducing transport weight by about 30 times compared to electric two-wheelers commonly used in India. The startup’s first drone model weighs 3.3 pounds and can carry up to 2.2 pounds, with a second version planned to carry 6.6 pounds while weighing only 2.6
robotdrone-technologyenergy-efficiencyaerospace-materialsdelivery-dronescarbon-fiberaerodynamicsUS pursues low-cost hypersonic missile with 4,000-pound thrust engine
The U.S. Air Force is developing an experimental hypersonic missile called "Angry Tortoise," aimed at demonstrating a lower-cost approach to hypersonic weaponry and ballistic threat simulation. Central to the project is the Draper rocket motor, a 4,000-pound-thrust liquid-fueled engine using a hydrogen peroxide–kerosene mix that can be stored at room temperature for extended periods, enhancing tactical readiness. About 60 percent of the motor's parts are 3D printed, enabling significant cost reductions compared to current hypersonic propulsion systems. The program leverages components from the existing Economical Target-2 (ET-2) rocket to further cut costs while improving performance. The first test flight is scheduled for December 2025 at White Sands Missile Range, initially targeting speeds near Mach 2, with potential to reach Mach 4 or Mach 5 in future iterations. The project is currently a science and technology demonstration rather than an immediate weapons deployment, with
energyhypersonic-missile3D-printingadditive-manufacturingrocket-propulsionmilitary-technologyaerospace-materials'World’s first' ship-based stealth drone may be deployed by China
China has unveiled the GJ-11 "Sharp Sword," which it claims to be the world’s first ship-launched stealth combat drone. Developed by Hongdu Aviation Industry Group under the Aviation Industry Corporation of China (AVIC), the drone evolved from the Shenyang Aircraft Corporation’s Sharp Sword project. Featuring a flying wing design and a fully blended body, the GJ-11 boasts low radar cross-section visibility enhanced by a specialized stealth coating. Measuring about 10 meters long with a 14-meter wingspan, it is powered by a turbofan engine capable of speeds up to 690 mph (1,111 km/h) and can carry a payload of up to 2,000 kg. Its design includes folding hinges to facilitate storage on aircraft carriers and amphibious assault ships. The GJ-11 is equipped with two internal weapons bays for guided bombs and can perform both strike and reconnaissance missions using multiple sensors. A notable capability is its function as a "loyal wingman," autonom
robotdronestealth-technologyunmanned-aerial-vehiclemilitary-technologyautonomous-systemsaerospace-materialsHow China's 12,400-mile-range nuclear missile stays launch-ready
China’s DF-5C is a newly unveiled liquid-fuel intercontinental ballistic missile (ICBM) boasting a range exceeding 20,000 kilometers (12,400 miles), significantly surpassing the U.S. Minuteman III’s range. As the latest upgrade in the Dongfeng-5 series, the DF-5C can reportedly carry up to 10 multiple independently targetable re-entry vehicles (MIRVs). A key feature highlighted during its military parade debut is its claimed ability to remain “always on alert and capable of striking anywhere in the world,” suggesting advances that allow the missile to stay launch-ready for extended periods despite the traditional challenges of liquid-fuel missiles, such as toxic fuels and complex fueling procedures. The DF-5C appears to incorporate technological innovations, such as flexible silver-grey materials around its engine nozzles, which may represent breakthroughs in rapid fueling or fuel storage, enabling constant readiness. Strategically, this enhances China’s second-strike nuclear capability, reinforcing its
energynuclear-missileliquid-fuel-technologymaterials-sciencestrategic-defensemissile-technologyaerospace-materialsChina warns US' shuttle-like craft could be used as 'space killer'
Chinese scientists have raised concerns about the U.S. military’s secretive X-37B space plane, warning it could be weaponized as a "space killer" and potentially used to maintain American space supremacy. The uncrewed, autonomous Boeing-designed craft, now on its eighth mission, has demonstrated advanced capabilities through multiple successful flights, covering over 1.3 billion miles and conducting various technology tests. Researchers from China’s Space Engineering University highlight that the X-37B’s dynamic and intelligent systems, enhanced by technologies like artificial intelligence and nuclear thermal propulsion, could integrate into the U.S. military’s Prompt Global Strike system, escalating space security risks and intensifying international competition. In response, China is advancing its own space capabilities with the reusable robotic Shenlong craft, which recently completed its third orbital test after 268 days in space. The Shenlong is suspected of signaling Earth while flying over North America in 2023, underscoring Beijing’s efforts to extend military reach into space and develop
robotspace-technologyautonomous-systemsmilitary-technologyartificial-intelligencespace-explorationaerospace-materialsNew carbon nanotube insulation can resist temperatures exceeding 4,700°F
Chinese researchers at Tsinghua University have developed a novel carbon nanotube-based insulation film capable of withstanding temperatures up to 4,712°F (2,600°C), significantly surpassing the limits of conventional insulators that typically fail above 2,732°F (1,500°C). This ultralight, porous, multilayered material is made by growing vertical carbon nanotube arrays and drawing them into thin sheets, which are then stacked or wound into layers. The structure effectively blocks all three modes of heat transfer—solid conduction, gas conduction, and radiative heat transfer—by exploiting the nanotubes’ nanoscale dimensions, pore size, and unique electronic properties that absorb and scatter infrared radiation. The new insulation exhibits an exceptionally low thermal conductivity of 0.004 W/mK at room temperature and 0.03 W/mK at 2,600°C, outperforming common high-temperature insulators like graphite felt, which has a thermal conductivity of 1.6 W/m
materialscarbon-nanotubeshigh-temperature-insulationthermal-conductivityaerospace-materialsenergy-applicationsnanotechnologyStronger next-gen 3D-printed titanium alloy developed for aerospace use
Engineers at the Royal Melbourne Institute of Technology (RMIT) have developed a new 3D-printed titanium alloy that is about one-third cheaper and stronger than the current industry standard, such as Ti-6Al-4V. This cost reduction is achieved by replacing the expensive element vanadium with more accessible, lower-cost materials. The new alloy also overcomes a common issue in 3D-printed metals by avoiding the formation of columnar microstructures, resulting in a uniform grain structure that enhances both strength and ductility. These improvements address key challenges that have hindered the widespread adoption of 3D-printed titanium in aerospace and medical device industries. The research introduces a novel framework for designing metallic alloys tailored specifically for additive manufacturing, moving beyond legacy alloys that limit the potential of 3D printing. The team has produced and tested samples at RMIT’s Advanced Manufacturing Precinct and is now seeking industry partners to help commercialize the alloy. A provisional patent has been filed for the
3D-printingtitanium-alloymaterials-scienceadditive-manufacturingaerospace-materialsmetal-alloyscost-effective-materialsUS firm's solid rocket motor with grain propellant tech tested
Colorado-based Ursa Major successfully conducted static fire tests of an upgraded solid rocket motor featuring its Highly Loaded Grain (HLG) propellant technology, which delivers increased performance and extended range without enlarging the motor’s size. Developed in collaboration with BAE Systems, this extended range variant is designed for the APKWS laser-guidance kit, a combat-proven system that converts unguided 2.75-inch rockets into precision-guided munitions (PGMs) with high accuracy and minimal collateral damage. The successful tests pave the way for a planned flight demonstration in fall 2025. Ursa Major’s next-generation motor incorporates a flexible design architecture compatible with multiple missile systems and integrates with its Lynx Manufacturing System, a software-enabled additive manufacturing line that enhances production speed and scalability. This approach aims to overcome legacy industrial bottlenecks and rapidly provide critical solid rocket motor capacity for the U.S. and allied forces. The APKWS system, qualified on numerous U.S. Department of Defense platforms
energysolid-rocket-motorgrain-propellantmissile-technologyadditive-manufacturingprecision-munitionsaerospace-materialsKARGO II: New VTOL drone can deliver 1,500 pounds of military goods
Piasecki Aircraft Corporation, a Pennsylvania-based firm, has introduced the KARGO II, an advanced vertical take-off and landing (VTOL) drone capable of autonomously delivering over 1,500 pounds (680 kilograms) of military cargo in a single flight. This payload capacity doubles that of its predecessor, the KARGO UAV, which could carry between 500 to 800 pounds. Designed for both military and commercial applications, KARGO II offers enhanced range, airspeed, and mission flexibility, enabling operations in contested and remote environments. It can deliver payloads with high precision using various methods, including hard-mounted pods like the Joint Modular Intermodal Container (JMIC), aerial delivery, or external long line, and can be deployed rapidly from a standard 20-foot cargo container. The drone incorporates a new optimized shaft-driven transmission and larger rotors to support its improved performance. Developed through a spiral approach building on successful flight tests and demonstrations under U.S. Army and Marine Corps contracts, KARGO
robotdroneautonomous-logisticsVTOLunmanned-aerial-vehiclemilitary-technologyaerospace-materialsNew self-healing plastic outperforms steel in strength tests
US researchers from Texas A&M University and the University of Tulsa have developed a new recyclable carbon-fiber plastic composite called Aromatic Thermosetting Copolyester (ATSP) that exhibits self-healing properties and outperforms steel in strength tests. Led by Dr. Mohammad Naraghi and funded by the US Department of Defense, ATSP can repair cracks and deformations when heated, restoring or even improving its original strength. This adaptive material shows promise for critical applications in aerospace, defense, and automotive industries, where it can enhance safety by enabling on-demand healing of damaged components and potentially restoring vehicle shapes after collisions. ATSP combines the flexibility of thermoplastics with the stability of thermosets, and when reinforced with carbon fibers, it becomes several times stronger than steel while remaining lighter than aluminum. The material’s chemistry remains stable over multiple reshaping cycles, making it a sustainable alternative to traditional plastics by reducing waste without sacrificing durability. Laboratory tests demonstrated that ATSP could endure hundreds of stress and
materialsself-healing-plasticcarbon-fiber-compositeadvanced-materialsaerospace-materialssustainable-materialssmart-materialsAnduril opens solid rocket motor factory amidst ongoing chemical chokepoint
Anduril has launched a high-volume solid rocket motor (SRM) factory in Mississippi, aiming to become the United States’ third major SRM supplier and break the longstanding duopoly held by Northrop Grumman and L3Harris’ Aerojet Rocketdyne. The factory is expected to produce 6,000 tactical motors annually by the end of 2026, supporting a range of applications from missile interceptors to deep-space probes. This expansion comes amid increased demand for weapons driven by geopolitical tensions such as the Russian invasion of Ukraine and conflicts in the South China Sea. The U.S. Department of Defense has supported new entrants like Anduril, Ursa Major, and X-Bow Systems with funding to move from prototype to commercialization. However, the SRM supply chain faces a critical bottleneck due to the reliance on ammonium perchlorate (AP), a key oxidizer produced at scale by only one qualified supplier, American Pacific (AMPAC) in Utah. Despite
energysolid-rocket-motorsdefense-manufacturingsupply-chainammonium-perchloratemissile-technologyaerospace-materialsNew heat-resistant plastic can be recycled endlessly without loss
Researchers at Texas A&M University, in collaboration with the University of Tulsa and supported by the U.S. Department of Defense and the Air Force Office of Scientific Research, have developed a new high-strength plastic called Aromatic Thermosetting Copolyester (ATSP) that can be recycled endlessly without losing quality. This innovative material is heat-resistant, ultra-durable, and capable of self-healing and shape recovery after damage, making it highly suitable for demanding industries such as aerospace, automotive, medical, and electronics manufacturing. When reinforced with carbon fibers, ATSP becomes several times stronger than steel while remaining lighter than aluminum, offering a combination of strength and lightness critical for high-performance applications. The research team conducted extensive testing, including cyclical creep and deep-cycle bending fatigue tests, demonstrating that ATSP can endure repeated stress and heat cycles while maintaining or even improving its durability. The material’s unique bond exchanges enable on-demand self-healing at elevated temperatures (around 160 °C to 280 °
materialsrecyclable-plasticheat-resistant-polymeraerospace-materialsself-healing-plasticsustainable-materialshigh-performance-materialsWorld's first 3D-printed rocket part survives cryogenic pressure test
A team at the Korea Institute of Industrial Technology (KITECH) has successfully produced the world’s first large titanium rocket fuel tank using 3D printing, specifically the Directed Energy Deposition (DED) process. This 640mm diameter tank, made from Ti64 titanium alloy, was fabricated by melting titanium wire layer-by-layer with a laser, then assembling two hemispheres through machining and welding. The entire manufacturing cycle took only a few weeks, significantly faster than traditional forging methods, which rely on fixed molds and are less adaptable for custom, large-scale parts. The 3D-printed fuel tank passed a critical cryogenic pressure test conducted by the Korea Aerospace Research Institute (KARI), withstanding pressures of 330 bar at -196°C, conditions simulating spaceflight environments. This milestone demonstrates that large additively manufactured titanium structures can endure extreme temperatures and pressures required for space applications, potentially revolutionizing aerospace manufacturing by reducing costs, lead times, and design constraints. However, further cyclic
3D-printingtitanium-alloyaerospace-materialscryogenic-pressure-testadditive-manufacturingDirected-Energy-Depositionspace-fuel-tankChina to rival SpaceX with first reusable rocket recovery vessel
China has taken a significant step toward competing with SpaceX in reusable rocket technology by launching its first rocket recovery drone ship, named Xingji Guihang (“Interstellar Return”). Developed by the Beijing-based private aerospace firm iSpace, this vessel is designed to autonomously reposition itself to capture rocket first stages returning from space, similar to SpaceX’s autonomous spaceport drone ships (ASDS). Measuring approximately 100 meters long and 42 meters wide, Xingji Guihang features a large recovery deck and employs a dynamic positioning system to precisely align with descending boosters. This development marks China as the second country, after the US, to operate an active rocket recovery drone ship. The drone ship is intended to support multiple Chinese rocket providers and is not exclusive to iSpace launches. It was specifically designed for iSpace’s upcoming SQX-3 rocket launch, scheduled for later in 2025. Currently undergoing testing, the vessel will travel from its construction site in Yangzhou down the Yangtze River to the
robotautonomous-vesselreusable-rocketspace-technologydrone-shipaerospace-materialsenergy-efficiencyMitsubishi Electric’s ME Innovation Fund Invests in Pale Blue, Startup Developing Water-based Propulsion Systems for Satellites - CleanTechnica
Mitsubishi Electric Corporation’s ME Innovation Fund has invested in Pale Blue Inc., a Japanese startup developing water-based propulsion systems for small satellites. This marks the fund’s 13th investment and aligns with the growing global demand for safer, cost-effective, and environmentally friendly satellite propulsion technologies amid the rapid expansion of satellite constellations. Pale Blue, founded in 2020 and originating from the University of Tokyo, utilizes proprietary technologies including low-pressure, ambient-temperature water vaporization and low-power plasma generation with oxidation resistance to create sustainable propulsion solutions. Water as a propellant offers significant advantages over conventional options, being safer, more affordable, widely available, and environmentally benign. The startup has successfully demonstrated its technology in orbit and is advancing its production capabilities. Through this investment, Mitsubishi Electric aims to strengthen technical collaboration with Pale Blue to enhance its space business competitiveness and contribute to sustainable space utilization. Pale Blue’s CEO, Jun Asakawa, emphasized the goal of enabling mobility in space as a core industry element,
energysatellite-propulsionwater-based-propulsionspace-technologysustainable-energyMitsubishi-Electricaerospace-materials990-lb missile that can hit stealth aircraft, ballistic threats tested
The ASTER B1 New Technology (B1NT) missile, developed by the European consortium Eurosam, has undergone successful live-fire testing at the DGA Essais de Missiles range in France. This upgraded 990-lb (450 kg) missile variant demonstrates enhanced capabilities to intercept advanced aerial threats, including stealth aircraft, low-signature cruise missiles, maneuvering short-range ballistic missiles, and hypersonic targets. The recent tests validated its long-range interception capacity, reaching up to 150 km, and showcased improvements in propulsion, control systems, and guidance technology based on a Ka-band seeker and new interception algorithms. Designed for integration within the next-generation SAMP/T NG air defense system, the ASTER B1NT offers a significant performance boost over previous versions. The SAMP/T NG system features advanced multifunction radar, digital command and control with enhanced data fusion, and improved mobility, enabling rapid deployment and interoperability with NATO air and missile defense networks. Eurosam highlights that the ASTER family
energymissile-technologypropulsion-systemsaerospace-materialsdefense-technologyguidance-systemselectronicsJoby Aviation and defense contractor L3Harris to test autonomous hybrid aircraft
Joby Aviation, known for developing commercial electric air taxis, is expanding its focus through a partnership with defense contractor L3Harris Technologies to develop an autonomous gas-turbine hybrid vertical take-off and landing (VTOL) aircraft for military applications. This new aircraft will be based on Joby’s existing S4 platform, which has traditionally featured an all-electric powertrain. However, under a government contract, Joby demonstrated a hybrid prototype capable of flying 521 miles—more than twice the range of its battery-electric version. The collaboration aims to leverage L3Harris’s expertise in defense technologies to integrate sensors, autonomy, communications, and payloads, creating a mission-capable aircraft suited for Department of Defense (DoD) needs. Flight testing of the hybrid VTOL is scheduled to begin in the fall, with operational demonstrations planned for 2026. Joby has been working with the DoD for nearly a decade, focusing on meeting critical requirements such as extended range and mission flexibility.
robotautonomous-aircrafthybrid-VTOLelectric-aviationdefense-technologyunmanned-systemsaerospace-materialsAIR lands $23M to bring its eVTOLs to the US
AIR, an eVTOL (electric vertical takeoff and landing) manufacturer, recently raised $23 million in a Series A funding round led by Entree Capital to support scaling production in Israel, hiring staff, and expanding into the U.S. market. The company offers two main aircraft: the piloted AIR ONE for personal or commercial taxi use, and an uncrewed cargo eVTOL designed for logistics and defense applications. Since delivering its first cargo eVTOL in late 2023, AIR has secured over 2,500 pre-orders for AIR ONE and plans to ship 15 cargo eVTOLs this year. The funding round aligns with recent U.S. regulatory developments, including an Executive Order promoting domestic drone and eVTOL development and updates to the FAA’s MOSAIC rule, which expands certification pathways for light sport aircraft (LSA). AIR’s cargo eVTOLs currently operate under Experimental Airworthiness Certificates (EAC), allowing limited flights during development and testing,
robotuncrewed-aerial-vehicleseVTOLdrone-technologyelectric-aircraftaerospace-materialsaviation-energy-systemsCarbon fiber goes green as German researchers ditch oil for algae
German researchers at the Technical University of Munich (TUM), through the GreenCarbon project, have developed an innovative process to produce aircraft-grade carbon fiber from photosynthetic microalgae instead of petroleum. By converting algae oils into glycerol and then into acrylonitrile—the key precursor for carbon fiber—they have created a bio-based alternative to the traditional fossil fuel-derived acrylonitrile. This method, refined in partnership with the Fraunhofer Institute and carbon manufacturer SGL Carbon, yields carbon fibers that match the mechanical strength and resilience of conventional fibers, enabling their use in high-performance applications without major changes to existing manufacturing processes. The project’s success was demonstrated when Airbus used the algae-derived carbon fiber to build components for a research helicopter that flew in 2024, marking a significant step toward sustainable aviation manufacturing. Beyond aerospace, the lightweight, strong materials have potential uses in wind turbines, vehicles, and sports equipment. Importantly, because microalgae absorb CO₂ during growth, this approach offers a
carbon-fibergreen-technologysustainable-materialsalgae-based-materialsrenewable-resourcesaerospace-materialsbio-based-compositesSilica from meteorites may hold key to controlling industrial heat
Researchers at Columbia University have identified a unique form of silicon dioxide called tridymite, originally found in meteorites and also present on Mars, which exhibits hybrid crystal-glass thermal properties. Unlike typical materials where thermal conductivity either decreases (crystals) or increases (glasses) with temperature, tridymite maintains a nearly constant thermal conductivity over a wide temperature range (80 K to 380 K). This discovery was made possible by applying a unified equation for heat conduction in both crystals and glasses, developed by Professor Michele Simoncelli’s team using machine learning to overcome computational challenges. Experimental validation was conducted on a tridymite sample from a 1724 meteorite found in Germany, confirming its intermediate atomic structure and stable heat conduction behavior. This breakthrough has significant implications for industrial heat management, particularly in sectors like electronics, aerospace, and steel manufacturing. For instance, tridymite could form in refractory bricks used in steel furnaces after prolonged thermal aging, potentially enabling more efficient heat control and reducing the
materialsthermal-conductivitysilicon-dioxidetridymiteheat-managementcrystal-glass-hybridaerospace-materialsCold War bunker in UK reborn as advanced rocket test facility
A former Cold War-era armored building near the Mull of Kintyre in the UK has been transformed into MachLab, an advanced rocket test and teaching facility. Originally part of a US Air Force refueling complex in the late 1980s, the structure’s robust design now provides a secure environment for experimental rocket engine firings. Located on the former RAF Machrihanish airbase, MachLab was developed through a collaboration between the University of Glasgow and industry partners, securing around £500,000 in funding, including support from the UK Space Agency. The facility is equipped to test rocket engines producing up to one tonne of thrust and aims to advance rocket propulsion research. MachLab also focuses on training the next generation of UK rocket engineers through programs like the Rocketry Research Teaching Training (R2T2) initiative led by the University of Glasgow. The facility supports the development of engines using various propellants—solid, liquid, and cryogenic—and provides detailed data collection on parameters such as
energyrocket-propulsionaerospace-materials3D-printingrocket-enginesspace-technologyadvanced-cooling-systemsChina’s new fast-cooled superalloy engines could power 6th-gen jets
Chinese researchers at Dalian University of Technology have developed a novel superalloy cooling technique that rapidly cools forged turbine discs using a uniform mist of high-speed water jets. This method achieves a cooling speed 3.75 times faster than conventional processes and improves crystal grain size distribution by fourfold. Such advancements enable turbine discs to better withstand extreme temperatures—up to 1,200°C—and mechanical stresses, which are critical for jet engine performance, thrust, efficiency, and lifespan. The breakthrough is seen as a key enabler for China’s next-generation military aviation programs, including sixth-generation stealth fighters and hypersonic platforms. This innovation addresses a longstanding challenge in China’s military aviation: the difficulty in producing reliable, high-performance jet engines, exemplified by delays in the J-20 stealth fighter’s engine development. The new cooling technology, combined with advanced superalloys like the DD6 and the in-development DD9, may help close the technology gap with Western countries. It is particularly relevant for
materialssuperalloyjet-enginescooling-technologyturbine-discsaerospace-materialshypersonic-propulsionNew shape memory alloys could build more efficient US fighter jets
US scientists at Texas A&M University have developed a novel approach to designing high-temperature shape memory alloys (HTSMAs) that could significantly enhance the efficiency and performance of US fighter jets, such as the F/A-18. These alloys enable components like jet wings to change shape—folding via electrical heating and cooling—without relying on heavy mechanical parts. This innovation promises lighter, more energy-efficient jets that can be readied faster for flight, addressing current limitations in aircraft carrier operations. The research team, led by Dr. Ibrahim Karaman and Dr. Raymundo Arroyave, combined artificial intelligence (AI) with high-throughput experimentation using a framework called Batch Bayesian Optimization (BBO). This data-driven method accelerates the discovery of optimal alloy compositions by predicting metal interactions and minimizing costly trial-and-error testing. Their approach not only speeds up materials development but also allows for tailoring alloys to specific functions, such as reducing energy loss or enhancing actuation performance in aerospace, robotics, and medical devices
materials-scienceshape-memory-alloyshigh-temperature-alloysmachine-learningAI-in-materialsaerospace-materialsenergy-efficiencyPhotos: 1000-pound 'Spaceshop' propels interstellar product delivery
Vollebak, in collaboration with SAGA Space Architects and Bang & Olufsen, has unveiled the "Spaceshop," a 1000-pound interstellar delivery vehicle that combines the functions of a spaceship and a mobile retail unit. Designed to envision the future of retail, the Spaceshop aims to bring products directly to consumers regardless of location, whether on Earth or in space. Constructed from aerospace-grade materials such as carbon, stainless steel, and anodized aluminum, the vehicle features durable exterior panels designed for global display tours. The design was led by Denmark-based SAGA Space Architects, known for their expertise in modular habitats for extreme environments, with aluminum panels processed at Bang & Olufsen’s Danish facility. The Spaceshop integrates high-fidelity audio technology from Bang & Olufsen, including eight powerful speakers capable of producing sound levels up to 120 decibels, enhancing its futuristic appeal. It serves as a unique platform to showcase innovative products like Vollebak’s Martian Aerogel
materialsaerospace-materialsanodized-aluminumcarbon-compositesarchitectural-engineeringinterstellar-deliveryadvanced-materialsWorld's most advanced jet's fuselages now delivered every 30 hours
Northrop Grumman has significantly advanced the manufacturing of the F-35 Lightning II fighter jet by employing cutting-edge technologies at its Integrated Assembly Line (IAL) in Palmdale, California. The IAL produces the center fuselage—a critical airframe component common to all three F-35 variants—at an impressive rate of one every 30 hours. This component includes key features such as the bifurcated inlet system, internal weapons bay, fuel reservoir, and inflight operating doors, all essential to the aircraft’s stealth and operational capabilities. To date, over 1,400 center fuselages have been delivered, supporting both U.S. and international customers. The IAL is described as one of the most advanced military aircraft manufacturing facilities, integrating robotics, automation, and data-driven analytics to enhance production quality and efficiency while maintaining tight engineering tolerances. The facility handles all F-35 variants on a single line and incorporates technologies like automated guided vehicles, robotic drilling, and mold-in
robotautomationadvanced-manufacturingaerospace-materialsrobotics-in-manufacturingdefense-technologyautomated-guided-vehicles3D-printed jet engine hits 13,000 feet in China’s maiden flight test
China has successfully conducted the maiden flight test of its first fully 3D-printed mini turbojet engine, which reached an altitude of 13,000 feet (4,000 meters) in the Inner Mongolia Autonomous Region. This 160-kilogram thrust-class engine was produced using a combination of additive manufacturing and multi-disciplinary topology optimization, allowing for complex, lightweight, and integrated components that traditional casting and forging methods cannot easily achieve. The development represents a significant technical milestone for China’s aerospace sector, potentially reducing its reliance on foreign-sourced engines and addressing longstanding challenges in metallurgy and precision engineering. While additive manufacturing is already established in the aerospace industry globally—with companies like GE Aviation and Pratt & Whitney using 3D-printed parts—China’s achievement lies in producing an entire flight-validated engine through these methods. The lightweight engine is expected to be particularly useful for unmanned aerial vehicles (UAVs). However, transitioning from a prototype to industrial-scale production poses challenges, including advancements in high-temperature
3D-printingadditive-manufacturingaerospace-materialsjet-engine-technologyadvanced-manufacturingmaterials-engineeringaerospace-innovationA European Startup's Spacecraft Made It to Orbit. Now It's Lost at Sea
The Exploration Company, a European startup focused on developing orbital spacecraft, recently conducted a test flight of its 2.5-meter diameter demonstration vehicle, Mission Possible, launched aboard SpaceX's Transporter 14 mission. The flight achieved several key milestones: successful launch, nominal payload operation in orbit, stabilization after separation, reentry, and reestablishment of communication post-blackout. However, contact was lost shortly before the capsule's planned ocean touchdown, likely due to a failure in the deployment of its parachutes—critical for safe recovery. The parachutes, sourced from US-based Airborne Systems and with proven flight heritage, were expected to deploy between Mach 0.8 and Mach 0.6, but the vehicle was ultimately lost at sea, marking a partial failure in the mission’s recovery objective. Despite this setback, the company communicated transparently and promptly, acknowledging the partial success and ongoing investigation into the root cause. Mission Possible was developed rapidly and cost-effectively, with a budget of
robotautonomous-navigationspacecraftspaceflightparachute-deploymentorbital-flightaerospace-materialsReusable Rockets Are All The Rage In China. Now Honda Wants In On The Fun. - CleanTechnica
The article highlights the growing momentum in China’s reusable rocket industry, following SpaceX’s pioneering efforts in rocket recovery and reuse. Traditionally, the first stage of rockets, which is the most expensive part, was discarded after launch, often sinking into the ocean. Reusing these stages significantly reduces the cost of space access. China has embraced a competitive, market-driven approach to space technology, with numerous companies—including Sepoch, Landspace, Space Pioneer, and the state-owned CASC—vying to develop recoverable rockets. Notably, Sepoch recently completed a successful test flight of a reusable liquid oxygen-methane rocket, achieving a smooth launch, controlled descent, and soft landing at sea. Landspace also conducted a powerful static fire test of its Zhuque-3 rocket, which uses methane-oxygen engines and stainless steel construction. In addition to these established players, Honda R&D, a subsidiary of Honda Motor Company, has entered the fray, successfully testing a smaller experimental reusable rocket. This
energyreusable-rocketsspace-technologyrocket-recoveryaerospace-materialsliquid-oxygen-methane-propulsionstainless-steel-rockets‘Major Anomaly’ Behind Latest SpaceX Starship Explosion
SpaceX's latest Starship rocket, designated Ship 36, exploded during a ground test at the company's Starbase facility in South Texas late Wednesday night. The explosion occurred shortly after the vehicle was loaded with super-cold methane and liquid oxygen propellants in preparation for a static fire test of its six Raptor engines. SpaceX described the incident as a "major anomaly" involving a high-pressure nitrogen tank, or composite overwrapped pressure vessel (COPV), inside the payload bay. Preliminary data suggests this nitrogen COPV failed below its proof pressure under conditions that should not have caused damage, marking a potential first failure of this design. All personnel were evacuated safely, and local authorities responded to the scene. The blast, visible and felt up to 30 miles away, dealt a significant setback to SpaceX's Starship program, which has faced multiple prototype losses during testing since 2020. The explosion also disrupts operations at Massey's Test Site, the only facility where SpaceX conducts proof
energySpaceXrocket-technologypropulsion-systemsmethane-fuelliquid-oxygenaerospace-materialsChina's new heat shield can beat thermal limit for hypersonic flights
Chinese scientists have developed a new carbide ceramic heat shield material capable of withstanding temperatures up to 3,600 degrees Celsius (6,512 degrees Fahrenheit) in oxidizing environments, surpassing the previous thermal limits for hypersonic flight materials. This breakthrough, detailed in the journal Advanced Materials, marks the first time a base material has reached such a high service temperature, breaking the longstanding 3,000-degree Celsius barrier. The ceramic is composed of elements including hafnium, tantalum, zirconium, and tungsten, and features a unique oxide layer structure that protects the tungsten skeleton from oxidation, enhancing its thermal resistance. The new material’s exceptional heat tolerance is critical for hypersonic aircraft and weapons, which require components that maintain structural integrity under extreme thermal stress. Unlike traditional metal alloys and heat shield tiles—such as those used on SpaceX’s Starship, which withstand around 1,371 degrees Celsius—this carbide ceramic can endure much higher temperatures, making it suitable for aerospace, weapons protection
materialscarbide-ceramichypersonic-flightheat-shieldhigh-temperature-resistanceaerospace-materialsthermal-protectionAIR ONE’s electric air taxi races toward first piloted flight by 2026
EDAG Group and AIR have formalized their partnership through a letter of intent to jointly develop and manufacture the AIR ONE electric air taxi, building on two years of collaboration. EDAG is responsible for producing key structural components, including folding wings, engine arms, and a modular cabin that can be reconfigured for passengers or cargo. The AIR ONE is designed in multiple variants, with a fully electric model offering about one hour of flight time and a payload capacity of 250 kilograms, while a hybrid version could extend the range up to 450 kilometers. Currently in assembly and testing, the AIR ONE features a compact design with a wingspan of 7 meters and a top speed of 155 mph (250 km/h). It boasts fast charging capabilities, reaching full charge in about one hour and 20%-80% charge in half that time, minimizing downtime. The cargo variant provides 70 cubic feet of space for transporting equipment such as pallets or stretchers. The $150,000 passenger edition has sold
electric-aircrafteVTOLenergy-storagehybrid-propulsionbattery-technologyelectric-mobilityaerospace-materialsChina to test satellite refueling in space as US spies watch closely
China is set to conduct a pioneering orbital refueling test involving two satellites, Shijian-21 and Shijian-25, in geostationary orbit (GEO). The test, scheduled for June 11, will see Shijian-25 transfer approximately 313 pounds (142 kg) of hydrazine fuel to Shijian-21, potentially extending the latter’s operational life by eight years. Developed by the Shanghai Academy of Spaceflight Technology, these satellites have already demonstrated complex orbital maneuvers, including Shijian-21’s 2022 docking with a defunct Beidou navigation satellite to move it to a graveyard orbit. This test marks China’s first on-orbit refueling attempt in GEO and represents a significant technological advancement. The United States is closely monitoring the operation through two surveillance satellites, USA 270 and USA 271, part of the Geosynchronous Space Situational Awareness Program. These US satellites have maneuvered to observe the Chinese satellites
energysatellite-technologyspace-refuelingorbital-dockingaerospace-materialsspace-technologysatellite-lifespan-extension