DART Additive Engineering (AE) is a cutting-edge hypersonic drone technology demonstrator developed by Hypersonix Launch Systems (Hypersonix), an aerospace engineering, design, and manufacturing company based in Australia.

The official announcement of the DART AE hypersonic drone system’s development was made by Hypersonix in November 2021, positioning it as a remarkable technology demonstrator.In January 2022, Hypersonix initiated a collaboration with Kratos Defense & Security Solutions, marking an important milestone in their partnership.Hypersonix’s hypersonic vehicles require a boost to reach Mach 5 and are equipped with scramjet engines. The SPARTAN, a 3D-printed, reusable, hydrogen-powered scramjet developed by Hypersonix, will serve as the power source for the DART AE and other hypersonic vehicles in the company’s product roadmap.

To further advance the development of the DART AE hypersonic drone, Hypersonix secured an $8 million grant from the Modern Manufacturing Initiative (MMI) Defence Translation stream in May 2022. The objective of the grant is to deliver a flight-ready UAV that will be flown to demonstrate the technology.

In March 2023, the US Defense Innovation Unit (DIU) selected Hypersonix to provide a high-speed test aircraft for testing hypersonic technologies as part of the Hypersonic and High-Cadence Airborne Testing Capabilities (HyCAT) program. The DART AE was chosen for this purpose, fulfilling the MMI deliverable and paving the way for future sales of the DART AE to the US Department of Defense. The HyCat program includes three planned flights, with the potential for additional orders without competitive tender once the technology is proven in flight.

In addition to the DIU channel, Hypersonix and Kratos expanded their existing relationship in August 2023 through an exclusive teaming agreement. This agreement allows them to offer the DART AE system, integrated with Kratos’ Zeus family of solid rocket motors, to the US market.

Kratos has made a commitment to procure a maximum of 20 DART AE systems from Hypersonix. This commitment comes after the successful completion and demonstration of the combined flight system, as outlined in the agreement. Anticipated for 2024, the initial test flight of the DART AE marks an important milestone in the project.In April 2023, Hypersonix formed a partnership with Rocket Lab USA, a launch services provider, to carry out the inaugural launch of the DART AE in the HyCAT program. Rocket Lab will supply its Hypersonic Accelerator Suborbital Test Electron (HASTE) rocket, which serves as a suborbital testbed launch vehicle. The HASTE rocket will propel the DART AE to its desired operational speed, allowing it to demonstrate its non-ballistic flight patterns, acceleration, and hypersonic capabilities.

Following the successful first flight, Kratos will acquire and deploy DART AEs for various clients within the US Department of Defense, utilizing its Zeus family of engines.The DART AE hypersonic system is equipped with a single SPARTAN scramjet engine. SPARTAN, an acronym for Scramjet Powered Accelerator for Reusable Technology Advancement, represents a fifth-generation, reusable hydrogen-powered scramjet engine developed by Hypersonix.

In addition to its zero carbon dioxide emissions, the clean-burning hydrogen fuel enables the engine to be ignited and shut down multiple times during a flight. This capability allows for a non-ballistic trajectory that conventional rockets cannot achieve. Combined with the integrated control surfaces on the DART AE fuselage, this grants the DART AE exceptional maneuverability at high speeds.

Moreover, the use of clean hydrogen fuel provides the DART AE with an extended range compared to other scramjets.

In June 2023, Hypersonix was granted a US patent for the technology utilized in the design of the SPARTAN scramjet. The fixed geometry of SPARTAN is a notable feature that facilitates its application in advanced manufacturing methods. The scramjet engine is constructed using Inconel 718 high-temperature alloy, enabling it to reach speeds of up to Mach 7.Furthermore, in June 2023, Hypersonix acquired a technological demonstration version of its hydrogen-powered scramjet, which was produced using high-temperature ceramic matrix composites (HT CMCs).

HT CMCs demonstrate the capability to endure multiple rounds of intense heating and rapid cooling, making them the favored material for Hypersonix’s forthcoming reusable hypersonic vehicles. By utilizing HT CMC instead of Inconel 718, the engine can withstand high temperatures experienced at a maximum speed of Mach 12.