Australia has successfully flown its first 3D-printed hypersonic aircraft, the DART AE, reaching speeds of Mach 8 during a test launch from Virginia. The mission marks a major step in validating advanced manufacturing and scramjet propulsion for future high-speed weapons.
On February 27, 2026, Hypersonix Launch Systems conducted the historic launch from Rocket Lab Launch Complex 2 at NASA’s Wallops Flight Facility. The DART AE rode atop Rocket Lab’s HASTE booster before its scramjet engine ignited in the upper atmosphere and accelerated the vehicle to its target speed.
The flight, designated “That’s Not a Knife” by Rocket Lab, took place under the US Department of Defense’s Innovation Unit. According to Rocket Lab, the mission aimed to validate 3D-printing techniques, high-temperature materials, and autonomous guidance systems under real hypersonic conditions.
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The DART AE is the world’s first hypersonic aircraft made entirely from high-temperature alloys using 3D printing. The 662-pound vehicle burns green hydrogen fuel in its air-breathing SPARTAN scramjet engine, offering a cleaner alternative to traditional rocket-powered systems.
During the mission, the HASTE booster accelerated the DART AE to Mach 5 before the scramjet ignited. The vehicle then climbed to about 16 miles altitude and reached its top speed of Mach 8, flying approximately 540 nautical miles before splashing down in the Atlantic Ocean.
Rocket Lab provided a live feed of the mission, but at Hypersonix’s request, all video was cut before fairing release and stage separation. The company prioritized collecting telemetry data over public visibility of the flight profile.
Dr Michael Smart, Hypersonix co-founder and former NASA research scientist, said the flight data is invaluable. “At these speeds and temperatures, there is no substitute for flight data,” he explained. “The results from this mission will directly shape the design of future operational hypersonic aircraft.”
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The test represents a significant milestone for Australian defense technology and its partnership with US agencies. Engineers will now compare telemetry from the actual flight against digital models created before launch to refine their designs.
