Saab’s internal innovation arm The Rainforest has laid out a plan to fly a demonstrator aircraft with a software-defined aircraft fuselage in 2026, marking a potential shift in how future air vehicles are designed and manufactured. The concept blends additive manufacturing, AI-driven design, and automated assembly to create highly adaptable airframe structures for next-generation unmanned systems.
According to FlightGlobal’s defence reporting, Saab described the initiative as part of its ongoing exploration into faster design-to-flight cycles, exemplified by the Ruby unmanned platform project. The plan reflects growing industry interest in flexible, digital aircraft structures that can be iterated rapidly and potentially reduce production lead times and costs.
What is a software-defined aircraft fuselage?
The concept involves designing and manufacturing airframe components using advanced digital workflows, where software drives structural design, optimization and production, much as software updates control avionics today.
This approach departs from traditional, tooling-dependent fabrication by using:
- additive manufacturing (3D printing)
- AI-driven design optimisation
- fixtureless robotic assembly
Early prototypes, including a five-metre fuselage section already proof-loaded structurally, have been produced without unique tooling and are set to be flight-tested on an unmanned vehicle in 2026.
A collaborative effort between Saab and Divergent Technologies underpins the project. Divergent’s Adaptive Production System integrates digital design, industrial laser powder fusion printing, and universal robotic assembly to build structural components rapidly.
Why this matters for aerospace innovation
Software-defined hardware represents a potential industry shift away from static manufacturing toward more dynamic, software-controlled production. Key advantages include:
- Part count reduction: Simplified structural elements can eliminate hundreds of traditional fasteners and assemblies.
- Design flexibility: Organic, load-path environments can be optimized beyond conventional engineering constraints.
- Faster iteration: Digital design changes may be integrated into manufacturing workflows without tooling overhaul.
For Saab, this aligns with its model-based engineering philosophy evident in programmes like the Gripen fighter, where software-centric development has shortened upgrade cycles and enhanced system agility.
The Ruby demonstrator’s role
The Ruby unmanned platform, powered by a General Electric J85 engine and featuring a 6–7 m wingspan, is designed to validate these manufacturing innovations under real flight conditions. Saab has already completed structural proof-loading for the fuselage element, a significant milestone toward flight test readiness.
This demonstrator is not a production aircraft but a technology testbed, intended to show how rapid digital design integration with advanced manufacturing can reduce costs and cycle times for future aerospace platforms.
Industrial and defence implications
- For Saab: Success could accelerate internal R&D cycles, influencing future manned and unmanned platforms.
- For defence OEMs: A software-defined hardware approach may open paths to cheaper, faster production and retrofitability.
- For broader aerospace: Lessons learned may inform civil aircraft manufacturing over the longer term, especially for bespoke or low-volume advanced structures.
What’s next?
Saab intends to proceed with flight tests in 2026, evaluating not just the technology’s feasibility but also its integration with autonomous systems and future production ecosystems.
If the programme succeeds, it could illustrate a broader trend toward digitally led aerospace production that blurs the line between software flexibility and traditional airframe design.
Sources Cited
- FlightGlobal, Saab innovation flight-test plan for Ruby vehicle with software-defined fuselage.
- Aviation Week, Saab plans software-defined fuselage flight in 2026 with Divergent collaboration.
- PRNewswire, Divergent and Saab deliver fuselages for integration and flight testing.
- Saab press coverage, context on software-defined manufacturing and innovation philosophy.
- Aerospace Global News, details on 3D-printed AI-optimized fuselage structure.
