News & Success Stories

DAYTON, Ohio — Carrying out the precision work required to keep the Air Force’s aging fleet of cargo planes, fighters and bombers in the air demands not only skill and technical knowledge, but also significant time when tasks are performed manually.

Shaped components made of titanium, steel, aluminum and other alloys or composite materials make up an aircraft’s skin, or exterior surface. As with other parts, the aircraft’s outer skin can experience cracking from stress, corrosion and fatigue and must eventually be replaced. Similarly, rivets securing the skin to the frame can rust or become disfigured, making them more difficult to remove.

Traditionally, maintainers remove rivets manually using a twist drill. This approach is not only expensive and labor-intensive, consuming an estimated 3 million hours of Air Force technician time each year, but also physically demanding. It can also result in defect rates of up to 20 percent.

Complicating the process, drill-hole patterns on replacement skins must exactly match those on the original structure. Replicating patterns drilled by hand decades ago increases both the complexity and cost of repairs.

With support from AFWERX and the Department of the Air Force (DAF), Wilder Systems, an Austin, Texas-based aerospace company, is working to address these challenges by leveraging robotics, software and artificial intelligence.

In fiscal 2024, the DAF spent $17 billion on depot-level aircraft maintenance, including replacing structural components, repairing engines and upgrading communications systems on platforms such as the B-1B, B-52 and F-16. Based on customer discovery interviews and Government Accountability Office data, Wilder Systems estimates rivet removal alone costs DAF depots roughly $1 billion annually.

Wilder Systems and AFWERX

Before founding Wilder Systems, Will Wilder worked as a controls engineer in the aerospace industry, where he gained insight into the challenges of maintaining aircraft fuselages.

In 2019, the company began working with AFWERX and the DAF to explore applications of robotics in aircraft sustainment. In 2021, Wilder Systems received a Phase I Small Business Innovation Research contract to develop an automated process for removing rivets and replicating drill-hole patterns on sheet metal.

The effort progressed to Phase II, during which the company developed a prototype in collaboration with the Rapid Sustainment Office. In 2022, Wilder Systems received a nearly $1.8 million Tactical Funding Increase (TACFI) to further mature the technology in partnership with the 509th Bomb Wing and Air Force Global Strike Command.

The company has since tested its Agile Manufacturing Robot system at the Oklahoma City Air Logistics Complex. During testing on B-52 engine cowlings, the system was used to remove rivets and drill new holes as part of scheduled maintenance.

A technical order allocated 108 hours for the repairs, including defastening and drilling as well as corrosion mitigation. While 91 hours were designated specifically for rivet removal and drilling, the system completed those tasks in 59 hours, a 35 percent reduction in time compared to manual methods.

The system successfully removed 4,639 of 5,514 fasteners, or 84 percent. The remaining fasteners were intentionally left in place due to access limitations. In additional testing, the system demonstrated the ability to remove undamaged steel fasteners on a B-1 aircraft component without requiring rework.

The company has since tested its Agile Manufacturing Robot system at the Oklahoma City Air Logistics Complex. During testing on B-52 engine cowlings, the system was used to remove rivets and drill new holes as part of scheduled maintenance.

A technical order allocated 108 hours for the repairs, including defastening and drilling as well as corrosion mitigation. While 91 hours were designated specifically for rivet removal and drilling, the system completed those tasks in 59 hours, a 35 percent reduction in time compared to manual methods.

The system successfully removed 4,639 of 5,514 fasteners, or 84 percent. The remaining fasteners were intentionally left in place due to access limitations. In additional testing, the system demonstrated the ability to remove undamaged steel fasteners on a B-1 aircraft component without requiring rework.

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Building on these results, the Phase II effort led to a three-year, $32.5 million Strategic Funding Increase (STRATFI) to deliver 10 systems and associated process engineering support. The company is also developing artificial intelligence-enabled capabilities for tasks such as rivet removal and non-destructive inspection.

Since first engaging with AFWERX, Wilder Systems has received eight Phase I contracts totaling $672,014 and seven Phase II contracts worth $8.6 million, not including the STRATFI award. The company has grown to 125 employees with operations in California, Oklahoma and Texas.

Wilder Systems’ work highlights how AFWERX programs support collaboration between the Department of the Air Force and industry to address maintenance challenges. Through phased funding and partnerships with operational units, the effort demonstrates an approach to developing and transitioning technologies aimed at improving efficiency and readiness across the force.

*Disclaimer: References to non-federal entities do not constitute or imply Department of War or Air Force endorsement of any company or organization.

About AFWERX

As the innovation arm of the DAF and a directorate within the Air Force Research Laboratory, AFWERX brings cutting-edge American ingenuity from small businesses and start-ups to address the most pressing challenges of the DAF. Headquartered at Wright-Patterson Air Force Base, Ohio, AFWERX employs military, civilian and contractor personnel executing an annual $1.4 billion annual budget. Since 2019, AFWERX has awarded over 10,400 contracts worth more than $7.24 billion to strengthen the U.S. defense industrial base and drive faster technology transition to operational capability. For more information, visit: afwerx.com.

DAYTON, Ohio – Through the AFWERX Small Business Innovation Research (SBIR) program, the Department of the Air Force partners with small businesses to develop technologies that address operational and training challenges. One example is work by Disruptive Electronic Warfare Machines (DEWM) on its Attritable Radar Target, or DART, system, which supports electronic warfare training by increasing target density and mobility.

DART is a man-portable radar threat system designed to replicate modern adversary signals. It can be set up in about 10 minutes and operated remotely, including beyond line of sight. Unlike legacy fixed training emitters, DART can be repositioned and reprogrammed, allowing instructors to create dynamic threat scenarios that reflect real-world conditions. Its software-defined open architecture supports a range of training requirements and has been demonstrated on truck-mounted, waterborne and autonomous platforms. The system has been tested with the F-16 Fighting Falcon, F-35 Lightning II, F-15EX Eagle II and EA-18G Growler. It also received Joint Frequency Allocation Panel, or JF-12, approval.

DART is a man-portable radar threat system designed to replicate modern adversary signals. It can be set up in about 10 minutes and operated remotely, including beyond line of sight. (Courtesy of Disruptive Electronic Warfare Machines)

DEWM, a U.S. Air Force veteran-founded small business, reached a key milestone in 2025 with the delivery of its 50th DART unit. AFWERX supported this progress through a Direct-to-Phase II (D2P2) SBIR award, which allows companies to advance technology development more quickly when prior work demonstrates readiness. In September 2025, AFWERX awarded the D2P2 SBIR to expand DART’s capabilities to X-band frequencies, building on earlier C-band development and proven S-band performance.

In October 2025, DART units were delivered for operational training use at Eglin Air Force Base, Florida, and Gulfport Combat Readiness Training Center, Mississippi. The deliveries marked a transition from test and development activities to operational training integration. The mobile systems allow instructors to replicate mobile surface-to-air missile threats, compared with fixed legacy emitters used in traditional training.

In 2025, DART advanced into Phase III SBIR contracts, representing the transition from research and development into production, delivery or sustained use with funding from operational organizations. Department of the Air Force organizations funding Phase III DART contracts included:

• 301st Operations Group, Joint Base Lewis-McChord, Washington, $1.1 million.
• U.S. Air Forces in Europe and Air Forces in Africa, $403,750.
• 99th Logistics Readiness Squadron, Nellis Air Force Base, Nevada, $120,400.
• 33rd Fighter Wing, Eglin Air Force Base, Florida, $101,200.

AFWERX’s SBIR program accelerates the transition of technologies like DART from early development into operational use. By aligning small business innovation with DAF needs, AFWERX fosters more adaptable and effective capabilities for today’s and future missions.

*Disclaimer: References to non-federal entities do not constitute or imply Department of War or Air Force endorsement of any company or organization.

EL SEGUNDO, Calif. — Starfish Space, with support from SpaceWERX, has developed a revolutionary space vehicle designed to service or remove satellites from orbit. The Tukwila, Washington-based aerospace firm’s Otter spacecraft, combined with its advanced software and docking device, enables satellite maneuverability, lifespan extension, and debris mitigation.

Since 2021, AFWERX has awarded Starfish Space 10 SBIR contracts and three STTR contracts, demonstrating the DAF’s commitment to innovative technologies. These contracts have supported the development of Starfish’s Otter spacecraft and its various components, including the Cetacean computer vision navigation software and the Nautilus docking device.

The DAF benefits significantly from Starfish Space’s technology, which enhances satellite-servicing capabilities, improves satellite maneuverability and resilience, and advances space-sustainability efforts. This aligns with the DAF’s goals of maintaining a technological advantage in space and ensuring the long-term viability of space operations.

Looking ahead, Starfish Space is advancing its technology and operational capabilities, securing significant contracts with the Space Force and NASA. A $37.5 million STRATFI contract will deploy the Otter spacecraft in geostationary orbit by 2026, while a $15 million NASA contract will utilize Otter for a debris inspection mission.

In May 2024, Space Systems Command (SSC) in partnership with SpaceWERX awarded Starfish Space a $37.5 million STRATFI contract. That agreement calls for Starfish to build, launch and operate an Otter satellite vehicle designed to conduct a docking mission to provide “augmented maneuver” capability for national security space assets. The effort is part of a strategic collaboration that also includes Space Safari, SSC’s Commercial Space Office as well as its Assured Access to Space organization.

With private funding exceeding $50 million, Starfish Space is poised to launch its first three Otter servicing vehicles in 2026, providing critical services to client satellites for Intelsat, the U.S. Space Force, and NASA.

In addition to its SBIR/STTR work, Starfish Space has also secured Phase III contracts with other government agencies and private companies.

In January 2026, Starfish in a news release stated it has received a $52.5 million contract from the Space Development Agency, part of Space Force, to dispose of satellites at the end of their operational lives. Under the agreement, Starfish will build, launch and operate an Otter spacecraft tasked with deorbiting satellites in the SDA’s Proliferated Warfighter Space Architecture (PWSA) network, a Low Earth Orbit (LEO) constellation, according to the company news release. The LEO, extends from 100 to 1,200 miles above Earth’s surface. SDA plans to place hundreds of satellites in this orbital region over the next few years.

The DAF’s partnership with Starfish Space is a key step towards maintaining its superiority in space and addressing the challenges of space resilience. Space superiority and orbital debris mitigation are priorities of both the Trump Administration and the Department of War (DOW).

*Disclaimer: References to non-federal entities do not constitute or imply Department of War or Air Force endorsement of any company or organization.

EL SEGUNDO, Calif. — The Challenge:

Today’s modern warfighter requires tactical visual advantages that transcend the capabilities of the human eye and traditional camera images; from patrols aiming to prevent an ambush under dense jungle canopies, to command centers looking to regain sight of isolated friendly personnel, Hyperspectral Imaging (HSI) capability provides the perfect edge for the warfighter to see what others cannot see in real time. While the National Security Strategy (NSS) emphasizes the imperative of maintaining technological superiority, Secretary Pete Hegseth– in his confirmation hearings and public statements– has underscored the focus on “lethality and innovation” and the necessity of rapidly fielding emerging technologies like HSI to counter threats and provide superior ISR capability.

Hyperspectral Imaging, by Orbital Sidekick:

HSI captures and processes information across a wide range of the electromagnetic spectrum, measuring hundreds of narrow spectral bands to provide precise visual identification and analysis of materials, and offering insights beyond the human eye and traditional photography.

HSI provides detailed spectral information and precise identification and analysis of materials, offering a significant advantage in reconnaissance, surveillance, and target identification, while also enhancing operational effectiveness and safety. This capability directly improves the warfighter’s ability to identify threats in a timely, precise, and comprehensive manner from space, such as through counter-concealment and denial, the detection of fabrics or materials beneath camouflage, change detection in the signature of the earth for mine location, and identification of regions of earth capable of successfully sustaining an airstrip without the need for on-ground inspection.

Orbital Sidekick & AFWERX:

In 2018, Orbital Sidekick applied for the AFWERX open call for innovative defense-related dual-purpose technologies/solutions with a clear Air Force stakeholder need, introducing their Spectral Intelligence analytics platform, a low-cost space-based hyperspectral data infrastructure that would allow for a constellation of small satellites to provide real-time data across the planet. In November 2018, AFWERX awarded Orbital Sidekick with a Phase 1 SBIR award totaling $75,000 to provide support for research in space-based tasking, ground-truthing and validation testing for specific Areas of Interest (AOI) within the Air Force and Space Force.

In March 2019, AFWERX awarded Orbital Sidekick with an additional STRATFI SBIR award totaling nearly $17,000,000 to further their research and development of the HSI technology. The STRATFI award, a key AFWERX mechanism, represented a major investment by Space Systems Command (SSC), a strategic decision to co-invest with private capital to accelerate the deployment of a constellation of satellites, recognizing that a small business alone could not bear the cost of this infrastructure.

In March 2023, OSK launched the GHOSt-1 and GHOSt-2 satellites into orbit. In April 2023, the GHOSt-3 was launched into orbit. All three satellites were commissioned, leading to the launch of GHOSt-4 and GHOSt-5 in March 2024. This growing constellation of satellites enables faster, more informed decisions and supports rapid threat detection, including the identification of chemical weapons, troop movements, and isolated personnel in near-real-time. The satellites also demonstrate critical support capabilities in search and rescue, combat operations, and disaster relief. Current key end-users include AFRL and NASIC.

As a result of AFWERX and SpaceWERX bringing HSI into the defensive industrial base via SBIRs, OSK has gained exposure to additional customers and facilitated further connection within the technological ecosystem. SpaceWERX facilitated the acceptance of HSI as a supported image format in the Global Data Marketplace (GDM), making OSK a successful distributor of imagery and data for any military end-user that utilizes the GDM.

Additional Applications for Orbital Sidekick’s HSI Technology:

Orbital Sidekick’s technology can also be utilized across additional sectors including energy and utilities, where HSI can monitor pipelines for leaks and damage, inspect powerlines for vegetation encroachment and faults, or assist in solar farm performance analysis. HSI can support environmental monitoring through water quality assessment, forest health monitoring, and pollution detection. In the agriculture sector, HSI can assess crop health, analyze soil, and predict crop yield. This dual-use versatility fulfills a key SBIR objective: ensuring that defense-funded innovations achieve commercial scale, thereby strengthening the industrial base and reducing long-term costs for the warfighter.

*Disclaimer: References to non-federal entities do not constitute or imply Department of War or Air Force endorsement of any company or organization.

WRIGHT-PATTERSON AIR FORCE BASE, Ohio — AFWERX, the Department of the Air Force’s innovation organization, accelerates the transition of commercial technologies into operational capability by supercharging the defense industrial base. Through the Small Business Innovation Research (SBIR) program, AFWERX provides small businesses with funding to advance high-risk, high-reward concepts from feasibility studies to fielded systems aligned with Department of the Air Force operational requirements.

Castelion Corporation, a Torrance, California-based nontraditional defense contractor founded in 2022, entered the SBIR program in 2023 with two Direct-to-Phase II awards from the Air Force Research Laboratory. The first, a $1.73 million contract awarded Sept. 11 for the Remote Sensing in a TEU (RESINATE) project, is developing deployable sensing capabilities that fit within a standard 20-foot shipping container, and the second, a $16.97 million award later that month under the Future Operational Capabilities for the U.S. program, is focused on maturing a low-cost missile concept.

In March 2024, Castelion received a Phase III SBIR in partnership with the U.S. Navy to mature a highly manufacturable hypersonic strike weapon. Phase III SBIR contracts allow companies to transition prototypes into products, services or processes for military or commercial use and may be awarded sole-source to the original SBIR developer. In October 2024, AFRL awarded an additional $55.8 million Phase III contract to continue development of low-cost, highly manufacturable long-range strike weapons.

On April 5, 2025, Castelion received a $1.39 million Phase II award for an advanced radar system. In May 2025, the company was selected for an AFWERX Strategic Funding Increase, aligning approximately $15 million in Air Force SBIR funding with $30 million in private investment and additional government funding to support transition from prototype to operational use. Across the STRATFI portfolio, 63.5% of supported companies have transitioned to Phase III.

Capabilities developed through these efforts informed the design and manufacturability of Castelion’s hypersonic missile system, which is undergoing integration with Army and Navy platforms. Government-coordinated testing included prototype vehicle launches at Dugway Proving Grounds, Utah, on Nov. 6, 2025, and at San Nicolas Island within the Point Mugu Sea Range, California, on Dec. 5, 2025, to collect performance data under operationally relevant conditions.

Castelion operates under firm, fixed-price contracts with milestone-based payments and has raised more than $450 million in private capital to expand manufacturing capacity and product development alongside government efforts.

As part of AFRL’s Deliver mission area, AFWERX structures each SBIR investment with defined transition pathways and award timelines averaging three to nine months to support delivery of operational capability across air, space and information domains while strengthening the defense industrial base.

*Disclaimer: References to non-federal entities do not constitute or imply Department of War or Air Force endorsement of any company or organization.

WRIGHT-PATTERSON AIR FORCE BASE, Ohio – Aerospace firm Electra has developed a hybrid-electric Ultra Short Takeoff and Landing (eSTOL) aircraft with support from AFWERX.

In June 2025, President Trump issued an executive order, “Unleashing American Drone Dominance,” to accelerate domestic drone production, secure U.S. airspace and position the nation as a leader in supersonic technology. Additionally,  The order also emphasized advanced air mobility by establishing a pilot program to test electric vertical takeoff and landing aircraft for cargo, defense logistics and related applications.

At the same time, the U.S. military is evaluating runway-independent aircraft capable of operating in austere and contested environments, including the Indo-Pacific. Hybrid-powered aircraft may support logistics, ship-to-shore transport, personnel recovery and other missions.

Since December 2020, Electra has received nine contracts from AFWERX. In 2023, AFWERX awarded the company a Strategic Funding Increase (STRATFI) of up to $85 million to develop a full-scale pre-production prototype eSTOL aircraft. The three-year contract – consisting of $30 million in Air Force SBIR and other funds as well as $55 million in private investment – supports flight testing that provides data for future military and commercial applications.

In September FY24, the Manassas, Virginia-based company successfully showcased its EL2 Goldfinch, a two-seater prototype, for AFWERX and other military stakeholders. The demonstrations at Marine Corps Air Facility Quantico and Felker Army Airfield at Joint Base Langley-Eustis, both in Virginia, highlighted the aircraft’s dual-use capabilities for logistics operations in austere environments. The flights included takeoffs and landings from grass fields, showcasing operations off-runway without the need for ground-support infrastructure. The pilot also displayed the aircraft’s low-altitude, low-speed maneuverability, further emphasizing its survivability in complex military scenarios.

This success story, which was first published in the AFWERX-SpaceWERX FY2024 Annual Report, has been updated since its initial release.

Electra is now developing the EL9, a nine-passenger aircraft. This version would be capable of carrying 1,000 lbs. over 1,000 nautical miles, and generating 600 kW of expeditionary power.

In December 2025, the company introduced Electra Defense, a business unit aimed at meeting defense mission needs with the EL9 aircraft. This aircraft can take off and land in spaces as short as 150 feet, enabling it to access helicopter-sized areas in austere or remote environments.

In September 2025, Electra participated in the at the Air Force Research Laboratory’’s Future Flag 25-3 exercise where it completed a series of government-directed tests, a milestone under its STRATFI contract with AFWERX and the Air Force. Additionally, in July,  the aerospace firm was awarded a research and development contract with the U.S. Army’s SBIR program to advance the research and development of hybrid-electric powertrain, power, and propulsion systems.

This year, Electra will continue fine tuning its EL9 for the commercial and defense markets and start flight testing in 2027. In addition to establishing its defense business, the company also has 2,200 provisional orders from more than 60 commercial customers worldwide. Providing support to the small businesses developing cutting-edge, dual-use technologies for the warfighter remains core to the AFWERX SBIR/STTR mission.

*Disclaimer: References to non-federal entities do not constitute or imply Department of War or Air Force endorsement of any company or organization.

EL SEGUNDO, Calif. — As on-orbit threats proliferate, the United States Space Force is working with the private sector to secure cutting-edge systems capable of deterring or countering adversaries’ aggressive or irresponsible actions in space.

The VICTUS HAZE program, launched in 2024, has engaged two space companies, True Anomaly and Rocket Lab USA, to provide the Space Force with tactically responsive space (TacRS) mission capabilities.

This success story, which was first published in the AFWERX and SpaceWERX FY 2024 Annual Report, has been updated since its initial release.

In April, Space Systems Command’s Space Safari Program Office, with funding from SpaceWERX and the Defense Innovation Unit (DIU), awarded contracts to the two companies.

Under the Emergent Need Small Business Innovation Research (SBIR) award, made by SSC’s Space Safari Program Office in partnership with SpaceWERX, the Space Force funded $30 million of the total $60 million effort. True Anomaly will leverage the remaining $30 million of private capital.

The second participating company, Rocket Lab, based in Long Beach, California, received $32 million in funding from DIU. The companies were each slated to demonstrate their ability to build rendezvous and proximity operation (RPO)-capable space vehicles and command and control centers, with a delivery target of fall 2025.

Once the build phase is complete, the mission will enter several successive phases, including “hot standby”—awaiting a rapid manifest and launch request.

The TacRS systems developed by these companies will position the Space Force to provide future capabilities to Combatant Commands, equipping them to conduct rapid operations in response to adversary on-orbit aggression.

The demonstration will also enable development of TacRS tactics, techniques and procedures when responding to adversary aggression on orbit.

Space Safari partnered with SpaceWERX for assistance in the technical and commercial evaluation of True Anomaly and the push for an emergent SBIR selection by Space Force leadership. Space Safari is leading the contract administration, providing programmatic oversight and will execute the mission using capabilities provided by True Anomaly.

The VICTUS HAZE program underscores the DAF’s commitment to leveraging private-sector innovation to address critical space challenges. By fostering collaboration among government organizations, industry and startups, the initiative supports the Space Force’s ability to maintain freedom of action in space.

True Anomaly began working with SpaceWERX in 2023 through the SpaceWERX TacRS Challenge, a program focused on gaining new technologies that will enable the Space Force to more rapidly and flexibly respond to emerging on-orbit threats by 2026.

*Disclaimer: References to non-federal entities do not constitute or imply Department of War or Air Force endorsement of any company or organization.