The manufacturer describes the Wingman model as a “fighter-type drone” that could be commanded by the pilot of an existing combat aircraft, such as the Eurofighter Typhoon.

Like a wingman in the traditional military aviation sense, it would support the mission lead with augmented capabilities. But unlike crewed fighter aircraft, it could take on high-risk missions that pose a threat to human personnel, receiving commands from a pilot that is shielded from exposure to risk.

“The German Air Force has expressed a clear need for an unmanned aircraft flying with and supporting missions of its manned fighter jets before the Future Combat Air System [FCAS] will be operational in 2040,” said Michael Schoellhorn, CEO of Airbus Defence and Space. “We will further drive and fine-tune this innovation made in Germany so that ultimately we can offer the German Air Force an affordable solution with the performance it needs to maximize the effects and multiply the power of its fighter fleet for the 2030s.”

FCAS is a European defense and security initiative aiming to develop a “system of systems” that delivers all of the capabilities and functionality of its constituent subsystems. Airbus co-leads the program alongside Dassault Aviation and Spain’s Indra Sistemas.

At the core of FCAS will be a Next Generation Weapon System, in which uncrewed remote carriers work together with a New Generation Fighter (NGF): a sixth-generation fighter jet intended to replace Germany’s Typhoons, France’s Dassault Rafales, and Spain’s McDonnell-Douglas EF-18 Hornets by the 2040s.

Both the uncrewed aircraft and NGF will be connected to a “Combat Cloud” comprising sensor nodes in space, in the air, on the ground, at sea and in cyberspace.

“[Remote carriers] will fly in close cooperation with manned aircraft, supporting pilots in their tasks and missions,” Airbus explains on its website. “Military transport aircraft such as Airbus’ A400M will play an important role: as motherships, they will bring the Remote Carriers as close as possible to their areas of operation before releasing up to 50 small—or as many as 12 heavy—remote carriers.”

According to Airbus, Wingman is designed to carry weapons and “other effectors.” It would be able to perform a range of tasks, including reconnaissance, target jamming, and firing missiles. Pilots would always be in control and act as the final decision makers from the safety of a larger aircraft, allowing the uncrewed aircraft to do the work.

“An additional focus is on increasing the overall combat mass in an affordable manner so that air forces can match the number of opposing forces in peers or near-peers in conflicts,” Airbus said Monday.

The company said the 1:1 Wingman model on display at ILA Berlin will be akin to a “show car,” featuring various concepts and capabilities that may not make it onto the final design.

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Over the course of two flights on May 15 and 16 at MacDill Air Force Base (KMCF) in Florida, engineers gathered data that will inform the development of the company’s autonomous flight system, Merlin Pilot. Intended to reduce the workload of pilots amid the ongoing pilot shortage—but not replace them, at least in the short term—the technology has also drawn the attention of government agencies, including the Air Force.

Merlin engineers observed Air Force pilots as they performed various tasks and maneuvers. The goal of the campaign was to identify areas where automation could be most useful for safety, efficiency, and cost savings. Teams gathered data on pilot priorities, for example, to implement automation in a way that could allow pilots to focus on the most critical tasks.

“The data collected during these flights is critical to our phased approach to autonomy, starting with reduced crew operations, and to materially evolving our advanced automation systems,” said Matt George, CEO of Merlin. “Being able to observe multiple aerial refueling flights and see exactly how pilots are focused on critical tasks like take-off, landing, and communications in operational military use cases has given us valuable insight.”

Physical assessments, observations, and crew interviews were conducted to determine how certain KC-135 operations could be integrated into the autonomous system.

The data will further be used to support a contract between Merlin, the Air Force, Air Mobility Command (AMC), and Air Force Materiel Command (AFMC) to design, integrate, test, and perform in-flight demos of Merlin Pilot on the aerial refueling tanker. The Air Force previously enlisted Merlin to explore reduced crew capabilities for the Lockheed Martin C-130J Hercules and is looking to automate other aircraft, such as the KC-46A Pegasus and UH-60A Blackhawk.

The FAA has also shown interest in Merlin, awarding it a $1 million contract for automated cargo network flight trials in Alaska, which the company completed successfully in July. Other aircraft that have been equipped with Merlin Pilot include the Beechcraft King Air, de Havilland Twin Otter, Cessna Caravan, Long-EZ, and Cozy Mark IV.

Merlin is seeking supplemental type certification from the FAA and has already obtained a Part 135 air operator certificate from New Zealand’s Civil Aviation Authority, which covers air operations for helicopters and small airplanes.

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Last week, Kendall got in the cockpit of a self-flying fighter plane during a historic flight at Edwards Air Force Base (KEDW) in California. The aircraft—called the X-62A Variable In-flight Simulator Test Aircraft, or VISTA for short—is a modified F-16 testbed and represents the Air Force’s first foray into aircraft flown entirely by machine learning AI models.

As Kendall and a safety pilot observed, the X-62A completed “a variety of tactical maneuvers utilizing live agents” during a series of test runs. Incredibly, the aircraft was able to simulate aerial dogfighting in real time, without Kendall or the safety pilot ever touching the controls. According to the Associated Press, VISTA flew at more than 550 mph and within 1,000 feet of its opponent—a crewed F-16—during the hourlong simulated battle.

“Before the flight, there was no shortage of questions from teammates and family about flying in this aircraft,” Kendall said. “For me, there was no apprehension, even as the X-62 began to maneuver aggressively against the hostile fighter aircraft.”

It wasn’t VISTA’s first rodeo. In September, the Air Force for the first time flew the uncrewed aircraft in a simulated dogfight versus a piloted F-16 at the Air Force Test Pilot School at Edwards. The department said autonomous demonstrations are continuing at the base through 2024. But Kendall’s decision to get into the cockpit himself represents a new vote of confidence from Air Force leadership.

“The potential for autonomous air-to-air combat has been imaginable for decades, but the reality has remained a distant dream up until now,” said Kendall. “In 2023, the X-62A broke one of the most significant barriers in combat aviation. This is a transformational moment, all made possible by breakthrough accomplishments of the ACE team.”

ACE stands for Air Combat Evolution, a Defense Advanced Research Projects Agency (DARPA) program that seeks to team human pilots with AI and machine-learning systems. The Air Force, an ACE participant, believes the technology could complement or supplement pilots even in complex and potentially dangerous scenarios—such as close-quarters dogfighting.

“AI is really taking the most capable technology you have, putting it together, and using it on problems that previously had to be solved through human decision-making,” said Kendall. “It’s automation of those decisions and it’s very specific.”

ACE developed VISTA in 2020, imbuing it with the unique ability to simulate another aircraft’s flying characteristics. The aircraft received an upgrade in 2022, turning it into a test vehicle for the Air Force’s AI experiments. 

VISTA uses machine learning-based AI agents to test maneuvers and capabilities in real time. These contrast with the heuristic or rules-based AI systems seen on many commercial and military aircraft, which are designed to be predictable and repeatable. Machine learning AI systems, despite being less predictable, are more adept at analyzing complex scenarios on the fly.

“Think of a simulator laboratory that you would have at a research facility,” said Bill Gray, chief test pilot at the Test Pilot School, which leads program management for VISTA. “We have taken that entire simulator laboratory and crammed it into an F-16, and that is VISTA.”

Using machine learning, VISTA picks up on maneuvers in a simulator before applying them to the real world, repeating the process to train itself. DARPA called the aircraft’s first human-AI dogfight in September “a fundamental paradigm shift,” likening it to the inception of AI computers that can defeat human opponents in a game of chess.

Since that maiden voyage, VISTA has completed a few dozen similar demonstrations, advancing to the point that it can actually defeat human pilots in air combat. The technology is not quite ready for actual battle. But the Air Force-led Collaborative Combat Aircraft (CCA) and Next Generation Air Dominance programs are developing thousands of uncrewed aircraft for that purpose, the first of which may be operational by 2028.

The goal of these initiatives is to reduce costs and take humans out of situations where AI could perform equally as well. Some aircraft may even be commanded by crewed fighter jets. The self-flying systems could serve hundreds of different purposes, according to Kendall.

Even within ACE, dogfighting is viewed as only one use case. The idea is that if AI can successfully operate in one of the most dangerous settings in combat, human pilots could trust it to handle other, less dangerous maneuvers. Related U.S. military projects, such as the recently announced Replicator initiative, are exploring AI applications in other aircraft, like drones.

However, autonomous weapons, such as AI-controlled combat aircraft, have raised concerns from various nations, scientists, and humanitarian groups. Even the U.S. Army itself acknowledged the risks of the technology in a 2017 report published in the Army University Press.

“Autonomous weapons systems will find it very hard to determine who is a civilian and who is a combatant, which is difficult even for humans,” researchers wrote. “Allowing AI to make decisions about targeting will most likely result in civilian casualties and unacceptable collateral damage.”

The report further raised concerns about accountability for AI-determined strikes, pointing out that it would be difficult for observers to assign blame to a single human.

The Air Force has countered that AI-controlled aircraft will always have at least some level of human oversight. It also argues that developing the technology is necessary to keep pace with rival militaries designing similar systems, which could be devastating to U.S. airmen.

Notably, China too is developing AI-controlled fighter jets. In March 2023, Chinese military researchers reportedly conducted their own human-AI dogfight, but the human-controlled aircraft was piloted remotely from the ground.

Leading U.S. defense officials in recent years have sounded the alarm on China’s People’s Liberation Army’s growing capabilities, characterizing it as the U.S. military’s biggest “pacing challenge.” The country’s AI flight capabilities are thought to be behind those of the U.S. But fears persist that it may soon catch up.

“In the not too distant future, there will be two types of Air Forces—those who incorporate this technology into their aircraft and those who do not and fall victim to those who do,” said Kendall. “We are in a race—we must keep running, and I am confident we will do so.”

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California-based MightyFly this week announced what the company is calling an “industry first” FAA authorization, granting it permission to test its recently unveiled 2024 Cento within a flight corridor between New Jerusalem Airport (1Q4) and Byron Airport (C83) in California.

MightyFly says the approval, obtained in March, is the first for a large, self-flying cargo eVTOL in the U.S., with “large” denoting a weight greater than 55 pounds. According to the FAA, the company’s UAS has a maximum takeoff weight of 550 pounds. MightyFly in January received an FAA special airworthiness certificate (SAC) and certificate of waiver or authorization (COA) to establish the corridor.

“This route is designed to connect the existing operating areas around the airports while ensuring the UAS does not overfly the city of Tracy or impact Stockton [Metropolitan Airport], which is Class D airspace,” the FAA told FLYING. “MightyFly needed the new authorization to operate in the area, but they could have started testing inside the operating areas that were previously approved.”

The firm’s March approval, which it obtained via Freedom of Information Act (FOIA) request, includes a COA authorizing a flight corridor up to 5,000 feet agl between New Jerusalem and Byron airports. The COA opens the ability for the company to perform what it terms “A-to-B flights” within the corridor’s general aviation airspace, allowing it to test aircraft range, among other things.

Following ground testing at its headquarters and test site, MightyFly began flying the 2024 Cento at the corridor’s origin airport on March 4. In the span of two months, the company has completed more than 30 autonomous flights, or about one every two days.

Future testing will include A-to-B flights. Eventually, it will expand to additional use cases and markets, MightyFly says.

“This is a solid vote of confidence from the FAA in our work and our ability to perform safe autonomous flights in the general aviation airspace,” said Manal Habib, CEO of MightyFly. “We now look forward to demonstrating point-to-point delivery flights with our partners in this space.”

The authorization also contains a SAC that will allow MightyFly to test Cento’s beyond visual line of sight (BVLOS) capabilities, which are considered key for enabling drone delivery at scale.

BVLOS refers to the drone operator’s ability (or lack thereof) to visually monitor the aircraft in the sky. In lieu of a final BVLOS rule, the FAA awards these permissions to select companies via waiver or exemption. But for safety reasons most companies must keep their drones within view of the operator.

However, technologies such as detect and avoid and remote identification have the potential to replace human observers as they mature. MightyFly will test Cento’s detect and avoid systems and long-range command and control (C2) datalink communications while the self-flying drone is trailed by a chase airplane.

The SAC also authorizes MightyFly to begin point-to-point autonomous deliveries and proof of concept demonstrations with customers and partners. These will include deliveries of medical and pharmaceutical supplies, spare parts and manufacturing components, and consumer goods within the flight corridor.

Future demonstrations include several planned point-to-point autonomous cargo delivery flights in Michigan under a contract with the state’s Office of Future Mobility and Electrification. The company is also scheduled to demonstrate Cento’s ability to autonomously load, unload, and balance packages for the U.S. Air Force in 2025. These flights, MightyFly says, will mark its “entry into the expedited delivery market.”

The 2024 Cento, MightyFly’s third-generation aircraft, is designed for expedited or “just-in-time” deliveries. Potential customers include manufacturers, medical teams, first responders, retailers, and logistics, automotive, and oil and gas companies.

The third-generation drone is built to carry up to 100 pounds of cargo over 600 sm (521 nm), cruising at 150 mph (130 knots). Under full autonomy, it is expected to be able to land at a fulfillment center, receive packages, fly to a destination, unload its cargo, and take off for its next delivery.

MightyFly’s Autonomous Load Mastering System (ALMS) autonomously opens and closes the cargo bay door, secures packages in (or ejects them from) the cargo hold, and senses the payload’s weight and balance to determine its center of gravity. The company is working with the Air Force and its Air Mobility Command to develop ALMS.

Another key differentiator for the 2024 Cento is its flexibility. The drone can handle a variety of cargo contents, densities, loading orders, and tie-down positions. That means customers won’t need to standardize their packaging or order loading processes to accommodate it. The aircraft can carry refrigeration boxes, for example, which are often used in the healthcare industry to transport organ donations or blood bags.

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The company introduced its latest flight simulator technology, AX-D Flex: a “roll-on, roll-off” solution designed to train pilots on multiple aircraft, from business jets to midsize airliners, within a single mothership. Each simulation bay can accommodate up to three different cockpits, which can be swapped out in two hours or less, the company says.

Roll-on, roll-off flight simulators—which allow pilots to train on a variety of aircraft within a single system—are uncommon, but not unheard of. CAE and GlobalSim, for example, sell systems billed as roll-on, roll-off.

However, Axis says its solution is the first such simulator with a front-loading mechanism, which makes it simpler to switch between cockpits. The nonsimulated area, where the instructor and observer sit, stays in the simulator.

“Training providers are typically required to install specific simulators for different aircraft types,” said Christian Theuermann, member of the Axis executive board. “The launch of AX-D Flex will redefine the landscape of flight simulation, offering a cost-effective solution that allows pilots to train a variety of different aircraft types.”

According to Axis, AX-D Flex enables software-based avionics simulation using commercial off-the-shelf components that are “OEM-quality” and is designed to reduce maintenance costs and pilot downtime.

The mothership houses AX-D Flex’s basic structures, including the core motion and visual display systems. Accompanying it are “swap units” comprising a cockpit module and base frame, which contains computers and other technical devices.

With the front-loading system—which uses a stationary forklift—the swap units, including larger cockpits, can be lifted from the mothership and replaced with new modules. A pilot could go from simulating a business jet like the Bombardier Challenger 300 to a midsize airliner such as the Boeing 737 Max within two hours.

The simulator interior’s track-mounted seats can be repositioned according to the cockpit being loaded in. The transition requires a maximum of two technicians, Axis says.

“Our hardware team has extensive experience in designing components that exceed industry standards,” said Helmut Haslberger, director of hardware development and production management for Axis. “Through our precision control and electrical systems, we’ve designed a seamless lifting mechanism to allow smooth transitions between cockpits.”

The U.S. military also has an interest in multipurpose simulators. The Defense Advanced Research Projects Agency (DARPA), for example, has modified an F-16 into an AI-controlled test aircraft that can simulate the conditions of other aircraft while flying. U.S. Air Force Secretary Frank Kendall earlier this month said he would get in the cockpit of the self-flying airplane. 

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Regent on Thursday announced it has signed memoranda of understanding (MOUs) with the Abu Dhabi Investment Office (ADIO) and the Emirate of Abu Dhabi’s Department of Municipalities and Transportation (DMT), with an eye toward building an electric seaglider ecosystem in the UAE. The manufacturer is targeting a “pilot operational campaign” in the country within the next few years.

The announcement was made at the inaugural DriftX, a two-day conference in Abu Dhabi showcasing the latest innovations in air, land, and sea transportation. The ADIO is one of the event’s main sponsors.

“With our growing backlog of $9 billion in seaglider orders rapidly spreading throughout the Gulf, the Red Sea, Indo-Pacific, and Europe, we need a way to effectively manufacture and deliver seagliders across the Eastern Hemisphere,” said Billy Thalheimer, co-founder and CEO of Regent. “We have been thrilled by the dedicated and rapid support of ADIO.”

Thalheimer told FLYING at DriftX that Regent believes the Middle East, which is flush with large cities lining coastal areas, is a key geographical market. As a company with global ambitions, it views Abu Dhabi—which sits near the center of the world’s hemispheric divide—as an ideal hub for manufacturing and other facilities.

Regent’s flagship, zero-emission seaglider, Viceroy, seats up to 12 passengers. With existing battery technology, the aircraft is capable of flying routes as long as 180 sm (156 nm) on a single charge. But the manufacturer predicts it will one day have a range of 500 sm (435 nm) as batteries improve.

Viceroy is designed to combine the speed of an aircraft (cruising at 180 mph or 156 knots) with the functionality and low operating cost of a boat. It will serve almost exclusively coastal regions and use existing dock infrastructure, flying 20 to 30 feet above the water using ground effect. Propulsion both in the air and on the water comes from the aircraft’s on-wing propellers, allowing the aircraft to move both forward and backward.

Interestingly, Viceroy operators are actually maritime captains—the vehicle’s only controls are boat controls, which are simpler than those on most aircraft. When flying, the captain can make the aircraft perform a left turn, for example, using these simplified controls. Landing is accomplished with the push of a button. But Regent will offer a roughly six-week training course that awards graduates with a seaglider endorsement, according to Thalheimer.

“I’m a pilot. A lot of our founding team members are pilots. And so much of pilot training is learning the feel, the stick and rudder, the takeoff, the flare,” Thalheimer told FLYING at DriftX. “You don’t need to do any of that in this vehicle because of the automatic flight control system that we’ve built.”

With ADIO, Regent will collaborate to localize seaglider development and manufacturing capabilities within Abu Dhabi’s Smart and Autonomous Vehicle Industry (SAVI) cluster, with the expectation that local manufacturing capabilities will be in place by the end of the decade.

SAVI, unveiled last year by ADIO and the Abu Dhabi’s Department of Economic Development (ADDED), comprises an urban hub of state-of-the-art facilities and services dedicated to advancing all forms of transportation within the Emirate.

“With immense speed and efficiency, I’m confident Abu Dhabi will see the global deployment of electric seagliders, and these will dramatically change how goods and people move between the world’s coastal areas going forward,” said Badr Al-Olama, director general of ADIO.

ADIO will also assist Regent with workforce development, supply chain efficiency, vehicle integration, and aircraft delivery infrastructure support.

Regent’s collaboration with Abu Dhabi’s DMT will largely center on the integration of electric seagliders into the UAE’s existing transportation network. The partners will focus on “high impact routes,” such as between the cities of Abu Dhabi and Ras Al Khaimah, at the country’s northern tip. Another example might be service between the Abu Dhabi mainland and the islands of Dalma and Sir Bani Yas, located more than 100 miles outside the city of Abu Dhabi.

Regent unveiled its first full-scale electric seaglider mockup in April 2023. Already, it says it has secured more than 600 aircraft orders, including one from Mesa Airlines—which works closely with United Airlines—for 200 aircraft.

Regent views coastal passenger transport as the biggest opportunity for its seaglider. However, the company also sees applications in sightseeing, cargo delivery, offshore logistics, maritime patrol, and more. All of these could potentially be developed in the UAE.

In 2022, Lockheed Martin Ventures and Yamato Holdings, a Japanese logistics and parcel delivery firm, made strategic investments in Regent. Lockheed Martin said its investment is meant to speed the development of seagliders for defense applications specifically.

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The Army on Thursday awarded a $1.9 million Small Business Innovation Research (SBIR) contract to Electra.aero, the manufacturer of a nine-passenger, hybrid-electric short takeoff and landing (eSTOL) design, to perform powered wind tunnel testing.

Similar to Electra’s other SBIR and Small Business Technology Transfer (SBTT) Phase II and III engagements with AFWERX, the innovation arm of the U.S. Air Force, the Army contract is a quid-pro-quo arrangement.

Electra will get the opportunity to leverage military test facilities as it collects data that will inform aircraft design and development. The Army, meanwhile, can explore the eSTOL’s unique capabilities—such as its miniscule runway requirement—for logistics operations in “contested” environments.

“There is a substantial benefit to employing the right-sized aircraft for a given payload-range mission,” said Ben Marchionna, director of technology and innovation at Electra. “Many of the most commonly deployed military logistics solutions in use today are flown well below their intended payload capacity. Our eSTOL aircraft can fulfill these missions while using dramatically less fuel, providing much more range, operating at significantly reduced noise levels, and utilizing the same constrained operational ground footprints.”

According to Electra, the eSTOL cruises at 175 knots and is capable of carrying up to nine passengers or 2,500 pounds of cargo. The company claims it will have more than twice the payload, 10 times the range, and 70 percent lower operating costs compared to electric vertical takeoff and landing (eVTOL) alternatives, while offering lower noise and fuel consumption.

The aircraft has a range of 500 nm for commercial use cases. But with range extensions, the Army will be able to fly it for 1,000 nm.

The defining feature of Electra’s design is its use of blown-lift technology, which redirects slipstream flows over the aircraft’s wings into large flaps and ailerons. By “multiplying lift,” as Electra puts it, the eSTOL can take off at just 35 mph, reducing the runway requirement to 150 feet.

Electra says it is the first manufacturer to deploy blown lift in an aircraft with a distributed electric propulsion system. That system takes the form of eight electric motors powered by a turbogenerator. The latter can run on both electricity or traditional aviation fuel and recharges the aircraft’s batteries in flight. Because of this, airports will not need to install electric aircraft chargers to accommodate it, Electra says.

The manufacturer intends to certify its flagship model as a fixed wing aircraft under FAR Part 23 and EASA CS-23, allowing it to be operated with a standard fixed wing pilot’s certificate. That removes a key hurdle facing the eVTOL industry, which will need to train a new generation of powered-lift-certified pilots under FAA proposals.

The Army will be one of the earliest users of the eSTOL, but Electra has plenty of commercial arrangements lined up. Those include more than 2,000 preorder sales of its flagship aircraft to major customers, among them American operators Bristow Group and JSX and India’s JetSetGo

This week, the manufacturer announced a partnership with Wilbur Air, the newly formed operator subsidiary of Australian vertiport developer Skyportz. Electra and Skyportz in 2021 signed a letter of intent for 100 aircraft.

Electra expects to begin eSTOL deliveries in 2028 following certification.

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For the past four years, DARPA has been developing its Air Combat Evolution (ACE) program, which seeks to team human pilots with AI and machine-learning systems in dogfighting scenarios. According to the agency, the initiative reached new heights in September with the first AI-versus-human dogfight conducted with actual aircraft.

During the test campaign, the agency says, the AI made no violations of training rules codifying airmen’s safety and ethical norms. In other words, it flew just as safely as a human pilot.

DARPA called the achievement “a fundamental paradigm shift,” similar to the inception of AI computers that can defeat human opponents in a game of chess. Chinese military researchers reportedly achieved a similar feat in March 2023, with one aircraft operated by AI and another controlled by a human on the ground.

Researchers also “pioneered new methods to train and test AI agent compliance with safety requirements, including flight envelope protection and aerial/ground collision avoidance, as well as with ethical requirements including combat training rules, weapons engagement zones, and clear avenues of fire,” the agency said.

This is significant because, according to DARPA, previous integrations of autonomy on crewed commercial and military aircraft have used heuristic or rules-based systems, which are designed for situations that are predictable or repeatable. More complex scenarios such as dogfighting are impractical for such a model because there are simply too many possibilities for which designers must account.

Machine-learning AI models are less predictable and explainable than rules-based models. But they are excellent for analyzing complex scenarios on the fly.

DARPA views AI dogfighting as “a means to an end,” in the sense that it intends for its findings to be applied to AI integration on military aircraft more broadly. Another goal is to foster trust in pilots toward machines. The idea is that if autonomy can operate in a scenario as dangerous as close-quarters combat, humans can trust it to work in less dangerous—but equally complex—situations.

“What is the most efficient and effective path to optimize the performance and safety of artificial intelligence in aerospace vehicles?” is the question the agency poses.

To evaluate AI for dogfighting, engineers developed the X-62A, a modified F-16 test aircraft also known as the Variable In-flight Simulator Test Aircraft (VISTA). Uniquely, VISTA is capable of simulating the conditions of other aircraft while flying.

“Think of a simulator laboratory that you would have at a research facility,” said Bill Gray, chief test pilot at the U.S. Air Force Test Pilot School at Edwards Air Force Base (KEDW) in California. “We have taken that entire simulator laboratory and crammed it into an F-16, and that is VISTA.”

Personnel began in 2020 by testing AI systems in a simulated environment using computers, progressing over the course of 21 test flights to actual flight controlled by ACE algorithms. Two human pilots remained in the cockpit for safety purposes.

The AI was retrained on a daily basis—engineers updated flight control laws overnight and reprogrammed the aircraft to fly the following morning. More than 100,000 lines of software changes were made over the course of testing.

The first dogfight between a crewed F-16 and ACE-controlled VISTA took place in September. The self-flying aircraft performed both defensive and offensive maneuvers, getting as close as 2,000 feet to the crewed aircraft at 1,200 mph.

All autonomous demonstrations took place at the Air Force Test Pilot School, where DARPA says they are continuing in 2024. The hope is that the results can be repeated during future testing of other scenarios. And researchers believe they could.

“Every lesson we’re learning applies to every task we could give to an autonomous system,” said Gray.

Like DARPA, the Air Force is committed to exploring autonomous flight systems. In addition to participating in ACE, the department is developing such technologies through AFWERX, its innovation arm. Last week, Air Force Secretary Frank Kendall told U.S. lawmakers that he would get in the cockpit of a self-flying plane—which the Air Force on Wednesday confirmed to be VISTA—in the near future.

“The potential for autonomous air-to-air combat has been imaginable for decades, but the reality has remained a distant dream up until now,” said Kendall. “In 2023, the X-62A broke one of the most significant barriers in combat aviation. This is a transformational moment, all made possible by breakthrough accomplishments of the X-62A ACE team.”

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Kendall said the flight is intended to allow him to observe the technology underlying the Air Force’s future fleet of Collaborative Combat Aircraft (CCA), which will pair crewed jets with fleets of tiny, buzzing, autonomous drones. A second pilot will join the Air Force secretary, but neither will actually fly the aircraft—a modified F-16—except in case of emergency.

The U.S. is investing plenty of money into the CCA. According to the Associated Press, the Air Force requested $559 million in its upcoming budget to support the program, out of a total budget request of $188.1 billion. The department’s 2025 fiscal year begins October 1. For the 2024 defense spending bill, the U.S. Department of Defense requested $1.8 billion worth of artificial intelligence investments.

“We have a cost problem with the aircraft that we’re buying now,” Kendall said in response to a question from Senator Susan Collins (R-Maine), vice chair of the Senate Appropriations Committee, during a hearing for the Air Force and Space Force fiscal year 2025 budget request. “Our fighters are very expensive. The F-35 and the F-15EX cost about $100 million each, NGAD (Next Generation Air Dominance) will cost over $300 million and will be bought in small numbers.

“The uncrewed Collaborative Combat Aircraft give us an opportunity to address the cost and the quantity issues with relatively inexpensive but very highly cost-effective platforms that we add to the fleet.”

The Air Force earlier this month welcomed three F-16s to Eglin Air Force Base (KVPS) in Florida, where they will be modified for autonomous testing. The modifications are part of the Viper Experimentation and Next-gen Operations Model-Autonomy Flying Testbed program, or VENOM-AFT, which supports CCA with funding for autonomous software testing on crewed and uncrewed aircraft.

VENOM-AFT testing will be performed by the Air Force’s 40th Flight Test Squadron and 85th Test and Evaluation Squadron. Personnel will monitor the autonomy system during flight and provide feedback.

Additionally, the Air Force Research Laboratory this month received a $4 million grant to build an AI and machine learning research center at Wright-Patterson Air Force Base (KFFO) in Ohio.

Kendall’s comments on Tuesday come amid the backdrop of China’s rising military might, particularly in the air.

Drones manufactured in China have been spotted on the battlefield in Eastern Europe and the Levant, where they have inflicted devastating attacks on troops, infrastructure, and civilians. Chinese manufacturer DJI is considered the largest seller of consumer drones. But many cheaply bought DJI products have been modified for use in combat, prompting wariness among U.S. lawmakers.

Kendall urged senators to modernize the department’s technology, warning that any further budget delays could give China a leg up. The budget for the current fiscal year was enacted in March, more than six months later than intended.

“Time matters, but so do resources,” Kendall said. “The United States is also now facing a competitor with national purchasing power that exceeds our own, a challenge we have never faced in modern times.”

Beyond the CCA, the DOD is also building up an army of “small, smart, cheap” drones through the Replicator initiative, announced by Defense Secretary Kathleen Hicks in August.

According to Hicks and other senior officials, the plan is to produce “multiple thousands” of systems that are attritable, meaning they could be lost or shot down with minimal impact to U.S. military capabilities. These drones would be ideal for high-risk operations in which the chance of a crash or takedown is likely.

Hicks said the objective is to “outmatch” China. But William LaPlante, undersecretary of defense for acquisition and sustainment, clarified that Replicator systems will be distinct from CCA aircraft. However, LaPlante added that Replicator drones could be “very complementary” to the CCA initiative.

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The company on Wednesday announced it completed the build of its Certification System Bench, a flight test simulator designed to speed its path to an STC. The simulator contains the company’s certifiable software and hardware components and is located at its Boston headquarters.

An STC is issued by a regulator when a company intends to modify an aerospace product from its initial, type-certified design. The approval authorizes the modification and how it will affect the original product.

In the case of Merlin, the company is seeking an STC from New Zealand’s Civil Aviation Authority (CAA) for Merlin Pilot, its platform-agnostic, takeoff-to-touchdown autonomy system for fixed-wing aircraft. Pilot uses an array of sensors to understand the state of the aircraft and its surroundings. The firm is working toward concurrent validation with the FAA through a Bilateral Aviation Safety Agreement between it and the CAA.

However, Merlin’s goal, at least in the short term, is not to remove the pilot from the cockpit entirely. Rather, it intends to supplement pilot workloads to combat the ongoing pilot shortage.

“In many ways, the Certification System Bench acts as a testing ‘funnel,’” said Sherif Ali, chief engineer for Merlin Pilot. “It allows us to test hundreds of cases with speed and ease, selecting edge cases to take to in-flight testing. As a result, we’re able to reduce the use of our test aircraft and keep it for limited cases only.”

The Certification System Bench will allow Merlin to test its automation systems from its headquarters, with no limitations due to factors such as weather, maintenance schedules, or pilot availability. The company says it provides a one-to-one replica of its in-flight technology, with three screens representing the pilot deck, instrument panels, and primary flight display.

The technology is equipped with the same software and hardware components found within the Pilot system. Further, cameras installed on the Bench allow Merlin’s global team to access it and perform testing remotely.

“With pilots on the Certification System Bench, we are able to learn multitudes about human factors while gaining accreditation towards our STC,” said Ali. “No other company in the sector has put more resources towards this type of testing simulator.”

According to Merlin, the Certification System Bench represents a “significant investment” for the firm—costing millions of dollars more than its actual aircraft—but one that will be worthwhile.

The company says ground tests on the Certification System Bench are accredited by aviation regulators, allowing those evaluations to contribute toward STC approval. Further, the technology should allow testing to become more routine. Technicians won’t need to worry about heavy rain or malfunctioning aircraft parts.

“Ensuring the Merlin Pilot is robust, safe, and reliable is our top priority, which underscores this [Certification] System Bench build as a huge milestone in Merlin’s certification journey,” said Matt George, founder and CEO of Merlin. “It took the team six months to design, vet solutions for, and build the Certification System Bench to extremely stringent specifications.”

Merlin is taking a “crawl-walk-run” approach to certification and operations, beginning with testing with the FAA and CAA, from which it recently obtained Part 135 operator approval. The next step will be to fly small aircraft with reduced crews, relying mostly on Pilot but augmented by a safety pilot. After that, the company intends to remove crews from small aircraft and reduce crews on larger aircraft.

Merlin received the first certification basis for an autonomous flight system from the CAA in 2023. Last year, Pilot also became the first autonomy system to secure U.S. National Airspace System integration and FAA validation, following agency-contracted uncrewed cargo network trials in Alaska, the company says.

Pilot so far has been integrated on five different aircraft types, including Dynamic Aviation’s fleet of Beechcraft King Airs and several aircraft from Ameriflight, the largest Part 135 cargo airline in the U.S.

Merlin further has a longstanding relationship with the U.S. Air Force, through which it has modified several military transport aircraft. In 2022, the company tested single-pilot crews aboard a Lockheed Martin C130J Hercules and conducted an autonomous refueling mission using a KC-46A Pegasus with no copilot.

In February, the partners extended their collaboration to demonstrate Pilot on a KC-135 Stratotanker. Merlin expects in-flight trials to begin next year, starting with a series of basic air refueling operations.

However, Merlin is not the only autonomous flight systems partner working with the Air Force. The department also has relationships with providers such as Xwing, Reliable Robotics, and rotorcraft manufacturer Sikorsky, which is developing an autonomy suite called Matrix.

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