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From: DarkAero <info@darkaero.com>
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July 2026 Recap
Growth continued at DarkAero throughout July. Development of the DarkAero=
1 advanced with completion of aileron control system proof load testing a=
nd the release of a new YouTube video highlighting the engine mount proof=
load test campaign. Manufacturing capabilities also continued to expand a=
s additional equipment was brought online and construction progressed on t=
he new shop space. The month concluded with the team attending EAA AirVent=
ure=2C where time was spent connecting with customers=2C supporters=2C and=
fellow aircraft builders.
The DarkAero team at EAA Airventure 2026
Aileron Control System
The aileron control system structural proof load test campaign was complet=
ed in July. With new bellcranks installed at the end of last month=2C the=
proof load testing proceeded through multiple different simulated aerodyn=
amic scenarios. The campaign started by applying loads to a near maximum r=
oll command=2C stick fixed control system configuration. This means one of=
the control sticks was constrained as if a pilot was holding it in a fixe=
d position near full aileron deflection. In this configuration=2C simulate=
d aerodynamic loads were applied to each aileron simultaneously with the r=
eaction load being introduced at the grip location on the control stick. W=
ith the test rig being easy to reconfigure for different loading and restr=
aint test cases=2C every proof load scenario was tested on each stick indi=
vidually=2C in both roll directions.
Part of the test setup to apply load to the ailerons of the DarkAero 1 pro=
totype.
Predicted aileron hinge moment values were combined with predicted lift lo=
ad values to proof load the control system hardware and supporting compone=
nts at the same time. After passing the predetermined stick fixed test cas=
es=2C the campaign moved on to loading the roll control stops. These test=
cases simulated ground gust conditions that could load the ailerons into=
maximum deflection positions if the pilot was not actively constraining t=
he stick. In this test case=2C the loads were reacted by the roll control=
stops. Finally=2C the test campaign was completed with simulated excessiv=
e pilot force application proof loads applied to the stick grip. These loa=
ds were also reacted by the roll control stops.
Now that the aileron control system has been structurally verified for fli=
ght and the primary components have essentially reached a design freeze=2C=
the final tasks can be efficiently completed to bring the system to a ful=
ly flightworthy state. These tasks include mass balancing=2C closeouts=2C=
and finalizing hardware stackups and respective torque values.
YouTube
A new YouTube video is out now covering the engine mount static load test=
campaign. The video covers the design and architecture of the engine moun=
t=2C the loads that it experiences in flight=2C and the testing that was c=
onducted to simulate flight loads.
Watch it here:
https://www.youtube.com/watch?v=3Ddf1mDyIoQnI
AirVenture 2026
Every year=2C DarkAero attends EAA AirVenture in Oshkosh=2C Wisconsin. Whi=
le AirVenture is widely known as the world's largest airshow=2C the team v=
iews it as much more than that. It is an opportunity to be immersed in the=
aviation industry=2C study exceptional engineering and craftsmanship=2C a=
nd learn from some of the world's best aircraft designers=2C builders=2C a=
nd manufacturers.
Rather than simply admiring the airplanes on display=2C the team approache=
s AirVenture with the goal of raising standards at DarkAero. Every aircraf=
t=2C manufacturing detail=2C and conversation is an opportunity to learn s=
omething new. Whether it's a clever engineering solution=2C an innovative=
manufacturing process=2C or an example of outstanding workmanship=2C the=
objective is to return with ideas that help make DarkAero's products and=
processes even better. The pursuit of excellence is a continuous journey=
=2C and AirVenture remains one of the best places in the world to sharpen=
skills=2C expand knowledge=2C and stay inspired by the broader aviation c=
ommunity.
The team also gathered for a group photo beneath the iconic Brown Arch bef=
ore meeting with members of the public to catch up and talk about airplane=
s!
DarkAero Careers
Team growth is ongoing=2C and several open positions are currently availab=
le. In particular=2C there is continued demand for Manufacturing Technicia=
ns to support the fabrication and assembly of advanced composite aerospace=
structures.
The work is hands-on with a strong emphasis on quality=2C craftsmanship=2C=
and attention to detail. Projects often present challenging technical pro=
blems=2C requiring both precision and adaptability. The work environment i=
s fast-paced and standards are high=2C with a corresponding sense of pride=
in what is being built.
Individuals who are motivated by building high-performance hardware and co=
ntributing to the development of new aircraft will find the work rewarding=
!
Join the Team! (https://www.darkaero.com/careers)
Courses
Molds are often viewed as the heart of composites manufacturing=2C but the=
y are only one element of the tooling required to produce composite aerosp=
ace structures. As composite assemblies increase in complexity=2C addition=
al tooling such as assembly fixtures=2C trim tools=2C drill jigs=2C inspec=
tion gauges=2C and workholding become equally important for achieving repe=
atability and precision.
The DarkAero Aerospace Mold and Tooling Course remains centered on the des=
ign and fabrication of composite molds while continuing to expand into add=
itional tooling concepts. Drawing from practical experience gained through=
both the DarkAero 1 program and contract manufacturing work=2C the course=
provides insight into the tooling strategies used to manufacture precisio=
n composite aerospace structures.
The next session of the DarkAero Aerospace Mold and Tooling Course is sche=
duled for August 6=E2=80=937. Additional information and registration are=
available here:
Sign up for the August 6=E2=80=937 Session of the DarkAero Aerospace Mold=
and Tooling Course! (https://www.darkaero.com/courses/mold-making)
DarkAero Capabilities
Composite manufacturing capability continued to expand with the addition o=
f a KR=C3=9CSS Mobile Surface Analyzer (MSA). The system provides quantita=
tive measurement of surface energy following surface preparation=2C allowi=
ng bond surfaces to be evaluated prior to adhesive bonding and secondary l=
amination. Surface energy is one of the primary metrics in determining the=
strength of a bond. Without any measurement of surface energy prior to bo=
nding=2C technicians must rely on more subjective=2C qualitative assessmen=
ts. Strict surface preparation procedures have already been established an=
d validated at DarkAero and are followed throughout bonding operations wit=
h specific quality checks. The MSA tool adds an extra layer of quality ass=
urance to verify that the surface preparation process is met and quantifia=
bly documented for each bonding operation.
Build-out continued on the new facility expansion as well. Work completed=
included larger overhead doors=2C painting=2C and floor resurfacing. Rema=
ining work includes more lighting and additional drop power. Beyond increa=
sed manufacturing space=2C the expansion provides additional offices to ac=
commodate the growing team.
Looking Ahead
In August=2C the new facility expansion will be completed=2C making room f=
or larger CNC equipment and enabling more streamlined material flow in the=
shop. A new YouTube video will be released in August covering the proof l=
oad testing of the aileron system. Team growth will remain a major focus a=
s well.
If you'd like to get more frequent updates on our progress and stay better=
connected with what we're up to=2C consider subscribing to our YouTube=2C=
Instagram=2C and LinkedIn accounts. Links to these pages can be found bel=
ow.
YouTube Channel: https://youtube.com/c/darkaeroinc (https://www.youtube.co=
m/c/darkaeroinc)
Instagram: https://instagram.com/darkaeroinc (https://www.instagram.com/da=
rkaeroinc)
LinkedIn: https://linkedin.com/company/darkaero-inc (https://www.linkedin.=
com/company/darkaero-inc)
X: https://x.com/darkaeroinc
=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=
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Copyright =C2=A9 2026 DARKAERO=2C INC=2C All rights reserved.
You are receiving this email because you opted in at our website. If you=
=E2=80=99d like to be taken off this mailing list=2C you may do so using t=
he unsubscribe link below.
DARKAERO=2C INC
6448 Ronald Reagan Ave
MADISON=2C WISCONSIN 53704
USA
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<body style=3D"height: 100%;margin: 0;padding: 0;width: 100%;-ms-text-=
size-adjust: 100%;-webkit-text-size-adjust: 100%;">
<!--
-->
<!--[if !gte mso 9]><!----><span class=3D"mcnPreviewText" style=
=3D"display:none; font-size:0px; line-height:0px; max-height:0px; max-widt=
h:0px; opacity:0; overflow:hidden; visibility:hidden; mso-hide:all;">Growt=
h continued at DarkAero throughout July. Development of the DarkAero 1 adv=
anced with completion of aileron control system proof load testing</span><=
!--<![endif]-->
<!--
-->
<center>
<table align=3D"center" border=3D"0" cellpadding=3D"0" cellspa=
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<td align=3D"center" valign=3D"top" id=3D"=
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<img align=3D"center" alt=3D"" src=
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t-text-size-adjust: 100%;">
=09<!--[if mso]>
=09=09=09=09<table align=3D"left" border=3D"0" cellspacing=3D"0" cellpaddi=
ng=3D"0" width=3D"100%" style=3D"width:100%;">
=09=09=09=09<tr>
=09=09=09=09<![endif]-->
=09=09=09
=09=09=09=09<!--[if mso]>
=09=09=09=09<td valign=3D"top" width=3D"600" style=3D"width:600px;">
=09=09=09=09<![endif]-->
<table align=3D"left" border=3D"0" cellpadding=3D"0" cells=
pacing=3D"0" style=3D"max-width: 100%;min-width: 100%;border-collapse: col=
lapse;mso-table-lspace: 0pt;mso-table-rspace: 0pt;-ms-text-size-adjust: 10=
0%;-webkit-text-size-adjust: 100%;float: left;" width=3D"100%" class=3D"mc=
nTextContentContainer">
<tbody><tr>
<td valign=3D"top" class=3D"mcnTextContent" style=
=3D"padding: 0px 18px 9px;color: #CCCCCC;mso-line-height-rule: exactly;-ms=
-text-size-adjust: 100%;-webkit-text-size-adjust: 100%;word-break: break-w=
ord;font-family: Helvetica;font-size: 16px;line-height: 150%;text-align: l=
eft;">
<div style=3D"text-align: center;"><em>July 20=
26 Recap</em></div>
</td>
</tr>
</tbody></table>
=09=09=09=09<!--[if mso]>
=09=09=09=09</td>
=09=09=09=09<![endif]-->
=09=09=09=09<!--[if mso]>
=09=09=09=09</tr>
=09=09=09=09</table>
=09=09=09=09<![endif]-->
</td>
</tr>
</tbody>
</table><table border=3D"0" cellpadding=3D"0" cellspacing=3D"0" width=3D"1=
00%" class=3D"mcnTextBlock" style=3D"min-width: 100%;border-collapse: coll=
apse;mso-table-lspace: 0pt;mso-table-rspace: 0pt;-ms-text-size-adjust: 100=
%;-webkit-text-size-adjust: 100%;">
<tbody class=3D"mcnTextBlockOuter">
<tr>
<td valign=3D"top" class=3D"mcnTextBlockInner" style=3D"paddin=
g-top: 9px;mso-line-height-rule: exactly;-ms-text-size-adjust: 100%;-webki=
t-text-size-adjust: 100%;">
=09<!--[if mso]>
=09=09=09=09<table align=3D"left" border=3D"0" cellspacing=3D"0" cellpaddi=
ng=3D"0" width=3D"100%" style=3D"width:100%;">
=09=09=09=09<tr>
=09=09=09=09<![endif]-->
=09=09=09
=09=09=09=09<!--[if mso]>
=09=09=09=09<td valign=3D"top" width=3D"600" style=3D"width:600px;">
=09=09=09=09<![endif]-->
<table align=3D"left" border=3D"0" cellpadding=3D"0" cells=
pacing=3D"0" style=3D"max-width: 100%;min-width: 100%;border-collapse: col=
lapse;mso-table-lspace: 0pt;mso-table-rspace: 0pt;-ms-text-size-adjust: 10=
0%;-webkit-text-size-adjust: 100%;float: left;" width=3D"100%" class=3D"mc=
nTextContentContainer">
<tbody><tr>
<td valign=3D"top" class=3D"mcnTextContent" style=
=3D"padding: 0px 18px 9px;color: #CCCCCC;mso-line-height-rule: exactly;-ms=
-text-size-adjust: 100%;-webkit-text-size-adjust: 100%;word-break: break-w=
ord;font-family: Helvetica;font-size: 16px;line-height: 150%;text-align: l=
eft;">
<p dir=3D"ltr" style=3D"color: #CCCCCC;margin:=
10px 0;padding: 0;mso-line-height-rule: exactly;-ms-text-size-adjust: 100=
%;-webkit-text-size-adjust: 100%;font-family: Helvetica;font-size: 16px;li=
ne-height: 150%;text-align: left;">Growth continued at DarkAero throughout=
July. Development of the DarkAero 1 advanced with completion of aileron c=
ontrol system proof load testing and the release of a new YouTube video hi=
ghlighting the engine mount proof load test campaign. Manufacturing capabi=
lities also continued to expand as additional equipment was brought online=
and construction progressed on the new shop space. The month concluded wi=
th the team attending EAA AirVenture=2C where time was spent connecting wi=
th customers=2C supporters=2C and fellow aircraft builders.</p>
</td>
</tr>
</tbody></table>
=09=09=09=09<!--[if mso]>
=09=09=09=09</td>
=09=09=09=09<![endif]-->
=09=09=09=09<!--[if mso]>
=09=09=09=09</tr>
=09=09=09=09</table>
=09=09=09=09<![endif]-->
</td>
</tr>
</tbody>
</table><table border=3D"0" cellpadding=3D"0" cellspacing=3D"0" width=3D"1=
00%" class=3D"mcnCaptionBlock" style=3D"border-collapse: collapse;mso-tabl=
e-lspace: 0pt;mso-table-rspace: 0pt;-ms-text-size-adjust: 100%;-webkit-tex=
t-size-adjust: 100%;">
<tbody class=3D"mcnCaptionBlockOuter">
<tr>
<td class=3D"mcnCaptionBlockInner" valign=3D"top" style=3D"pad=
ding: 9px;mso-line-height-rule: exactly;-ms-text-size-adjust: 100%;-webkit=
-text-size-adjust: 100%;">
<table align=3D"left" border=3D"0" cellpadding=3D"0" cellspacing=3D"0" cla=
ss=3D"mcnCaptionBottomContent mcnBlockFloatLeft" style=3D"border-collapse:=
collapse;mso-table-lspace: 0pt;mso-table-rspace: 0pt;-ms-text-size-adjust=
: 100%;-webkit-text-size-adjust: 100%;float: left;">
<tbody><tr>
<td class=3D"mcnCaptionBottomImageContent" align=3D"center" valign=
=3D"top" style=3D"padding: 0 9px 9px 9px;mso-line-height-rule: exactly;-ms=
-text-size-adjust: 100%;-webkit-text-size-adjust: 100%;">
<img alt=3D"" src=3D"https://mcusercontent.com/abdf8c3b04e519f=
9b6e413937/images/ae3cd2e1-c7ef-9014-7b46-843b45262c95.jpeg" width=3D"564"=
style=3D"max-width: 1200px;border: 0;height: auto;outline: none;text-deco=
ration: none;-ms-interpolation-mode: bicubic;vertical-align: bottom;" clas=
s=3D"mcnImage">
</td>
</tr>
<tr>
<td class=3D"mcnTextContent" valign=3D"top" style=3D"padding: 0px=
9px;color: #CCCCCC;font-style: italic;font-weight: normal;mso-line-height=
-rule: exactly;-ms-text-size-adjust: 100%;-webkit-text-size-adjust: 100%;w=
ord-break: break-word;font-family: Helvetica;font-size: 16px;line-height:=
150%;text-align: left;" width=3D"564">
<div style=3D"text-align: center;">The DarkAero team at EAA Ai=
rventure 2026</div>
</td>
</tr>
</tbody></table>
</td>
</tr>
</tbody>
</table><table border=3D"0" cellpadding=3D"0" cellspacing=3D"0" width=3D"1=
00%" class=3D"mcnTextBlock" style=3D"min-width: 100%;border-collapse: coll=
apse;mso-table-lspace: 0pt;mso-table-rspace: 0pt;-ms-text-size-adjust: 100=
%;-webkit-text-size-adjust: 100%;">
<tbody class=3D"mcnTextBlockOuter">
<tr>
<td valign=3D"top" class=3D"mcnTextBlockInner" style=3D"paddin=
g-top: 9px;mso-line-height-rule: exactly;-ms-text-size-adjust: 100%;-webki=
t-text-size-adjust: 100%;">
=09<!--[if mso]>
=09=09=09=09<table align=3D"left" border=3D"0" cellspacing=3D"0" cellpaddi=
ng=3D"0" width=3D"100%" style=3D"width:100%;">
=09=09=09=09<tr>
=09=09=09=09<![endif]-->
=09=09=09
=09=09=09=09<!--[if mso]>
=09=09=09=09<td valign=3D"top" width=3D"600" style=3D"width:600px;">
=09=09=09=09<![endif]-->
<table align=3D"left" border=3D"0" cellpadding=3D"0" cells=
pacing=3D"0" style=3D"max-width: 100%;min-width: 100%;border-collapse: col=
lapse;mso-table-lspace: 0pt;mso-table-rspace: 0pt;-ms-text-size-adjust: 10=
0%;-webkit-text-size-adjust: 100%;float: left;" width=3D"100%" class=3D"mc=
nTextContentContainer">
<tbody><tr>
<td valign=3D"top" class=3D"mcnTextContent" style=
=3D"padding: 0px 18px 9px;color: #CCCCCC;mso-line-height-rule: exactly;-ms=
-text-size-adjust: 100%;-webkit-text-size-adjust: 100%;word-break: break-w=
ord;font-family: Helvetica;font-size: 16px;line-height: 150%;text-align: l=
eft;">
<p dir=3D"ltr" style=3D"color: #CCCCCC;margin:=
10px 0;padding: 0;mso-line-height-rule: exactly;-ms-text-size-adjust: 100=
%;-webkit-text-size-adjust: 100%;font-family: Helvetica;font-size: 16px;li=
ne-height: 150%;text-align: left;"><strong>Aileron Control System</strong>=
<br>
The aileron control system structural proof load test campaign was complet=
ed in July. With new bellcranks installed at the end of last month=2C the=
proof load testing proceeded through multiple different simulated aerodyn=
amic scenarios. The campaign started by applying loads to a near maximum r=
oll command=2C stick fixed control system configuration. This means one of=
the control sticks was constrained as if a pilot was holding it in a fixe=
d position near full aileron deflection. In this configuration=2C simulate=
d aerodynamic loads were applied to each aileron simultaneously with the r=
eaction load being introduced at the grip location on the control stick. W=
ith the test rig being easy to reconfigure for different loading and restr=
aint test cases=2C every proof load scenario was tested on each stick indi=
vidually=2C in both roll directions. </p>
</td>
</tr>
</tbody></table>
=09=09=09=09<!--[if mso]>
=09=09=09=09</td>
=09=09=09=09<![endif]-->
=09=09=09=09<!--[if mso]>
=09=09=09=09</tr>
=09=09=09=09</table>
=09=09=09=09<![endif]-->
</td>
</tr>
</tbody>
</table><table border=3D"0" cellpadding=3D"0" cellspacing=3D"0" width=3D"1=
00%" class=3D"mcnCaptionBlock" style=3D"border-collapse: collapse;mso-tabl=
e-lspace: 0pt;mso-table-rspace: 0pt;-ms-text-size-adjust: 100%;-webkit-tex=
t-size-adjust: 100%;">
<tbody class=3D"mcnCaptionBlockOuter">
<tr>
<td class=3D"mcnCaptionBlockInner" valign=3D"top" style=3D"pad=
ding: 9px;mso-line-height-rule: exactly;-ms-text-size-adjust: 100%;-webkit=
-text-size-adjust: 100%;">
<table align=3D"left" border=3D"0" cellpadding=3D"0" cellspacing=3D"0" cla=
ss=3D"mcnCaptionBottomContent mcnBlockFloatLeft" style=3D"border-collapse:=
collapse;mso-table-lspace: 0pt;mso-table-rspace: 0pt;-ms-text-size-adjust=
: 100%;-webkit-text-size-adjust: 100%;float: left;">
<tbody><tr>
<td class=3D"mcnCaptionBottomImageContent" align=3D"center" valign=
=3D"top" style=3D"padding: 0 9px 9px 9px;mso-line-height-rule: exactly;-ms=
-text-size-adjust: 100%;-webkit-text-size-adjust: 100%;">
<img alt=3D"" src=3D"https://mcusercontent.com/abdf8c3b04e519f=
9b6e413937/images/5218001c-7328-ab07-4889-87d8aa563f91.gif" width=3D"564"=
style=3D"max-width: 800px;border: 0;height: auto;outline: none;text-decor=
ation: none;-ms-interpolation-mode: bicubic;vertical-align: bottom;" class=
=3D"mcnImage">
</td>
</tr>
<tr>
<td class=3D"mcnTextContent" valign=3D"top" style=3D"padding: 0px=
9px;color: #CCCCCC;font-style: italic;font-weight: normal;mso-line-height=
-rule: exactly;-ms-text-size-adjust: 100%;-webkit-text-size-adjust: 100%;w=
ord-break: break-word;font-family: Helvetica;font-size: 16px;line-height:=
150%;text-align: left;" width=3D"564">
<div style=3D"text-align: center;">Part of the test setup to a=
pply load to the ailerons of the DarkAero 1 prototype.</div>
</td>
</tr>
</tbody></table>
</td>
</tr>
</tbody>
</table><table border=3D"0" cellpadding=3D"0" cellspacing=3D"0" width=3D"1=
00%" class=3D"mcnTextBlock" style=3D"min-width: 100%;border-collapse: coll=
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<tbody class=3D"mcnTextBlockOuter">
<tr>
<td valign=3D"top" class=3D"mcnTextBlockInner" style=3D"paddin=
g-top: 9px;mso-line-height-rule: exactly;-ms-text-size-adjust: 100%;-webki=
t-text-size-adjust: 100%;">
=09<!--[if mso]>
=09=09=09=09<table align=3D"left" border=3D"0" cellspacing=3D"0" cellpaddi=
ng=3D"0" width=3D"100%" style=3D"width:100%;">
=09=09=09=09<tr>
=09=09=09=09<![endif]-->
=09=09=09
=09=09=09=09<!--[if mso]>
=09=09=09=09<td valign=3D"top" width=3D"600" style=3D"width:600px;">
=09=09=09=09<![endif]-->
<table align=3D"left" border=3D"0" cellpadding=3D"0" cells=
pacing=3D"0" style=3D"max-width: 100%;min-width: 100%;border-collapse: col=
lapse;mso-table-lspace: 0pt;mso-table-rspace: 0pt;-ms-text-size-adjust: 10=
0%;-webkit-text-size-adjust: 100%;float: left;" width=3D"100%" class=3D"mc=
nTextContentContainer">
<tbody><tr>
<td valign=3D"top" class=3D"mcnTextContent" style=
=3D"padding: 0px 18px 9px;color: #CCCCCC;mso-line-height-rule: exactly;-ms=
-text-size-adjust: 100%;-webkit-text-size-adjust: 100%;word-break: break-w=
ord;font-family: Helvetica;font-size: 16px;line-height: 150%;text-align: l=
eft;">
<p dir=3D"ltr" style=3D"color: #CCCCCC;margin:=
10px 0;padding: 0;mso-line-height-rule: exactly;-ms-text-size-adjust: 100=
%;-webkit-text-size-adjust: 100%;font-family: Helvetica;font-size: 16px;li=
ne-height: 150%;text-align: left;">Predicted aileron hinge moment values w=
ere combined with predicted lift load values to proof load the control sys=
tem hardware and supporting components at the same time. After passing the=
predetermined stick fixed test cases=2C the campaign moved on to loading=
the roll control stops. These test cases simulated ground gust conditions=
that could load the ailerons into maximum deflection positions if the pil=
ot was not actively constraining the stick. In this test case=2C the loads=
were reacted by the roll control stops. Finally=2C the test campaign was=
completed with simulated excessive pilot force application proof loads ap=
plied to the stick grip. These loads were also reacted by the roll control=
stops.<br>
<br>
Now that the aileron control system has been structurally verified for fli=
ght and the primary components have essentially reached a design freeze=2C=
the final tasks can be efficiently completed to bring the system to a ful=
ly flightworthy state. These tasks include mass balancing=2C closeouts=2C=
and finalizing hardware stackups and respective torque values.</p>
</td>
</tr>
</tbody></table>
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=09=09=09=09<![endif]-->
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</td>
</tr>
</tbody>
</table><table border=3D"0" cellpadding=3D"0" cellspacing=3D"0" width=3D"1=
00%" class=3D"mcnTextBlock" style=3D"min-width: 100%;border-collapse: coll=
apse;mso-table-lspace: 0pt;mso-table-rspace: 0pt;-ms-text-size-adjust: 100=
%;-webkit-text-size-adjust: 100%;">
<tbody class=3D"mcnTextBlockOuter">
<tr>
<td valign=3D"top" class=3D"mcnTextBlockInner" style=3D"paddin=
g-top: 9px;mso-line-height-rule: exactly;-ms-text-size-adjust: 100%;-webki=
t-text-size-adjust: 100%;">
=09<!--[if mso]>
=09=09=09=09<table align=3D"left" border=3D"0" cellspacing=3D"0" cellpaddi=
ng=3D"0" width=3D"100%" style=3D"width:100%;">
=09=09=09=09<tr>
=09=09=09=09<![endif]-->
=09=09=09
=09=09=09=09<!--[if mso]>
=09=09=09=09<td valign=3D"top" width=3D"600" style=3D"width:600px;">
=09=09=09=09<![endif]-->
<table align=3D"left" border=3D"0" cellpadding=3D"0" cells=
pacing=3D"0" style=3D"max-width: 100%;min-width: 100%;border-collapse: col=
lapse;mso-table-lspace: 0pt;mso-table-rspace: 0pt;-ms-text-size-adjust: 10=
0%;-webkit-text-size-adjust: 100%;float: left;" width=3D"100%" class=3D"mc=
nTextContentContainer">
<tbody><tr>
<td valign=3D"top" class=3D"mcnTextContent" style=
=3D"padding: 0px 18px 9px;color: #CCCCCC;mso-line-height-rule: exactly;-ms=
-text-size-adjust: 100%;-webkit-text-size-adjust: 100%;word-break: break-w=
ord;font-family: Helvetica;font-size: 16px;line-height: 150%;text-align: l=
eft;">
<p dir=3D"ltr" style=3D"color: #CCCCCC;margin:=
10px 0;padding: 0;mso-line-height-rule: exactly;-ms-text-size-adjust: 100=
%;-webkit-text-size-adjust: 100%;font-family: Helvetica;font-size: 16px;li=
ne-height: 150%;text-align: left;"><strong>YouTube</strong><br>
A new YouTube video is out now covering the engine mount static load test=
campaign. The video covers the design and architecture of the engine moun=
t=2C the loads that it experiences in flight=2C and the testing that was c=
onducted to simulate flight loads.<br>
<br>
Watch it here: </p>
</td>
</tr>
</tbody></table>
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=09=09=09=09<![endif]-->
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</td>
</tr>
</tbody>
</table><table border=3D"0" cellpadding=3D"0" cellspacing=3D"0" width=3D"1=
00%" class=3D"mcnImageCardBlock" style=3D"border-collapse: collapse;mso-ta=
ble-lspace: 0pt;mso-table-rspace: 0pt;-ms-text-size-adjust: 100%;-webkit-t=
ext-size-adjust: 100%;">
<tbody class=3D"mcnImageCardBlockOuter">
<tr>
<td class=3D"mcnImageCardBlockInner" valign=3D"top" style=3D"p=
adding-top: 9px;padding-right: 18px;padding-bottom: 9px;padding-left: 18px=
;mso-line-height-rule: exactly;-ms-text-size-adjust: 100%;-webkit-text-siz=
e-adjust: 100%;">
<table align=3D"right" border=3D"0" cellpadding=3D"0" cellspacing=3D"0" cl=
ass=3D"mcnImageCardBottomContent" width=3D"100%" style=3D"border-collapse:=
collapse;mso-table-lspace: 0pt;mso-table-rspace: 0pt;-ms-text-size-adjust=
: 100%;-webkit-text-size-adjust: 100%;float: right;">
<tbody><tr>
<td class=3D"mcnImageCardBottomImageContent" align=3D"left" valign=
=3D"top" style=3D"padding-top: 0px;padding-right: 0px;padding-bottom: 0;pa=
dding-left: 0px;mso-line-height-rule: exactly;-ms-text-size-adjust: 100%;-=
webkit-text-size-adjust: 100%;">
<a href=3D"https://us.list-manage.com/QE2EF3O9P5H?e=3Dcd183fa7a5&c2id=3Dd9e848cdbaa68931fa253ab5d1e9938c" title=3D"" class=3D"" target=3D"" style=3D"mso-=
line-height-rule: exactly;-ms-text-size-adjust: 100%;-webkit-text-size-adj=
ust: 100%;">
<img alt=3D"" src=3D"https://mcusercontent.com/abdf8c3b04e519f=
9b6e413937/video_thumbnails_new/856ae059a88ff71dd481c21397c407d2.png" widt=
h=3D"564" style=3D"max-width: 640px;border: 0;height: auto;outline: none;t=
ext-decoration: none;-ms-interpolation-mode: bicubic;vertical-align: botto=
m;" class=3D"mcnImage">
</a>
</td>
</tr>
<tr>
<td class=3D"mcnTextContent" valign=3D"top" style=3D"padding: 9px=
18px;font-family: Helvetica;font-size: 14px;font-weight: normal;text-alig=
n: center;mso-line-height-rule: exactly;-ms-text-size-adjust: 100%;-webkit=
-text-size-adjust: 100%;word-break: break-word;color: #757575;line-height:=
150%;" width=3D"546">
</td>
</tr>
</tbody></table>
</td>
</tr>
</tbody>
</table><table border=3D"0" cellpadding=3D"0" cellspacing=3D"0" width=3D"1=
00%" class=3D"mcnTextBlock" style=3D"min-width: 100%;border-collapse: coll=
apse;mso-table-lspace: 0pt;mso-table-rspace: 0pt;-ms-text-size-adjust: 100=
%;-webkit-text-size-adjust: 100%;">
<tbody class=3D"mcnTextBlockOuter">
<tr>
<td valign=3D"top" class=3D"mcnTextBlockInner" style=3D"paddin=
g-top: 9px;mso-line-height-rule: exactly;-ms-text-size-adjust: 100%;-webki=
t-text-size-adjust: 100%;">
=09<!--[if mso]>
=09=09=09=09<table align=3D"left" border=3D"0" cellspacing=3D"0" cellpaddi=
ng=3D"0" width=3D"100%" style=3D"width:100%;">
=09=09=09=09<tr>
=09=09=09=09<![endif]-->
=09=09=09
=09=09=09=09<!--[if mso]>
=09=09=09=09<td valign=3D"top" width=3D"600" style=3D"width:600px;">
=09=09=09=09<![endif]-->
<table align=3D"left" border=3D"0" cellpadding=3D"0" cells=
pacing=3D"0" style=3D"max-width: 100%;min-width: 100%;border-collapse: col=
lapse;mso-table-lspace: 0pt;mso-table-rspace: 0pt;-ms-text-size-adjust: 10=
0%;-webkit-text-size-adjust: 100%;float: left;" width=3D"100%" class=3D"mc=
nTextContentContainer">
<tbody><tr>
<td valign=3D"top" class=3D"mcnTextContent" style=
=3D"padding: 0px 18px 9px;color: #CCCCCC;mso-line-height-rule: exactly;-ms=
-text-size-adjust: 100%;-webkit-text-size-adjust: 100%;word-break: break-w=
ord;font-family: Helvetica;font-size: 16px;line-height: 150%;text-align: l=
eft;">
<p dir=3D"ltr" style=3D"color: #CCCCCC;margin:=
10px 0;padding: 0;mso-line-height-rule: exactly;-ms-text-size-adjust: 100=
%;-webkit-text-size-adjust: 100%;font-family: Helvetica;font-size: 16px;li=
ne-height: 150%;text-align: left;"><strong>AirVenture 2026</strong><br>
Every year=2C DarkAero attends EAA AirVenture in Oshkosh=2C Wisconsin. Whi=
le AirVenture is widely known as the world's largest airshow=2C the team v=
iews it as much more than that. It is an opportunity to be immersed in the=
aviation industry=2C study exceptional engineering and craftsmanship=2C a=
nd learn from some of the world's best aircraft designers=2C builders=2C a=
nd manufacturers.<br>
<br>
Rather than simply admiring the airplanes on display=2C the team approache=
s AirVenture with the goal of raising standards at DarkAero. Every aircraf=
t=2C manufacturing detail=2C and conversation is an opportunity to learn s=
omething new. Whether it's a clever engineering solution=2C an innovative=
manufacturing process=2C or an example of outstanding workmanship=2C the=
objective is to return with ideas that help make DarkAero's products and=
processes even better. The pursuit of excellence is a continuous journey=
=2C and AirVenture remains one of the best places in the world to sharpen=
skills=2C expand knowledge=2C and stay inspired by the broader aviation c=
ommunity.<br>
<br>
The team also gathered for a group photo beneath the iconic Brown Arch bef=
ore meeting with members of the public to catch up and talk about airplane=
s!</p>
</td>
</tr>
</tbody></table>
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</td>
</tr>
</tbody>
</table><table border=3D"0" cellpadding=3D"0" cellspacing=3D"0" width=3D"1=
00%" class=3D"mcnTextBlock" style=3D"min-width: 100%;border-collapse: coll=
apse;mso-table-lspace: 0pt;mso-table-rspace: 0pt;-ms-text-size-adjust: 100=
%;-webkit-text-size-adjust: 100%;">
<tbody class=3D"mcnTextBlockOuter">
<tr>
<td valign=3D"top" class=3D"mcnTextBlockInner" style=3D"paddin=
g-top: 9px;mso-line-height-rule: exactly;-ms-text-size-adjust: 100%;-webki=
t-text-size-adjust: 100%;">
=09<!--[if mso]>
=09=09=09=09<table align=3D"left" border=3D"0" cellspacing=3D"0" cellpaddi=
ng=3D"0" width=3D"100%" style=3D"width:100%;">
=09=09=09=09<tr>
=09=09=09=09<![endif]-->
=09=09=09
=09=09=09=09<!--[if mso]>
=09=09=09=09<td valign=3D"top" width=3D"600" style=3D"width:600px;">
=09=09=09=09<![endif]-->
<table align=3D"left" border=3D"0" cellpadding=3D"0" cells=
pacing=3D"0" style=3D"max-width: 100%;min-width: 100%;border-collapse: col=
lapse;mso-table-lspace: 0pt;mso-table-rspace: 0pt;-ms-text-size-adjust: 10=
0%;-webkit-text-size-adjust: 100%;float: left;" width=3D"100%" class=3D"mc=
nTextContentContainer">
<tbody><tr>
<td valign=3D"top" class=3D"mcnTextContent" style=
=3D"padding: 0px 18px 9px;color: #CCCCCC;mso-line-height-rule: exactly;-ms=
-text-size-adjust: 100%;-webkit-text-size-adjust: 100%;word-break: break-w=
ord;font-family: Helvetica;font-size: 16px;line-height: 150%;text-align: l=
eft;">
<p dir=3D"ltr" style=3D"color: #CCCCCC;margin:=
10px 0;padding: 0;mso-line-height-rule: exactly;-ms-text-size-adjust: 100=
%;-webkit-text-size-adjust: 100%;font-family: Helvetica;font-size: 16px;li=
ne-height: 150%;text-align: left;"><strong>DarkAero Careers</strong><br>
Team growth is ongoing=2C and several open positions are currently availab=
le. In particular=2C there is continued demand for Manufacturing Technicia=
ns to support the fabrication and assembly of advanced composite aerospace=
structures.<br>
<br>
The work is hands-on with a strong emphasis on quality=2C craftsmanship=2C=
and attention to detail. Projects often present challenging technical pro=
blems=2C requiring both precision and adaptability. The work environment i=
s fast-paced and standards are high=2C with a corresponding sense of pride=
in what is being built.<br>
<br>
Individuals who are motivated by building high-performance hardware and co=
ntributing to the development of new aircraft will find the work rewarding=
!<br>
<br>
<a href=3D"https://us.list-manage.com/eB4hVNqdOQD?e=3Dcd183fa7a5&c2id=3Dd9e848cdbaa68931fa253ab5d1e9938c" target=3D"_blank" style=3D"mso-line-height-rule: exactly;-m=
s-text-size-adjust: 100%;-webkit-text-size-adjust: 100%;color: #007C89;fon=
t-weight: normal;text-decoration: underline;">Join the Team!</a></p>
</td>
</tr>
</tbody></table>
=09=09=09=09<!--[if mso]>
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=09=09=09=09<![endif]-->
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=09=09=09=09</table>
=09=09=09=09<![endif]-->
</td>
</tr>
</tbody>
</table><table border=3D"0" cellpadding=3D"0" cellspacing=3D"0" width=3D"1=
00%" class=3D"mcnTextBlock" style=3D"min-width: 100%;border-collapse: coll=
apse;mso-table-lspace: 0pt;mso-table-rspace: 0pt;-ms-text-size-adjust: 100=
%;-webkit-text-size-adjust: 100%;">
<tbody class=3D"mcnTextBlockOuter">
<tr>
<td valign=3D"top" class=3D"mcnTextBlockInner" style=3D"paddin=
g-top: 9px;mso-line-height-rule: exactly;-ms-text-size-adjust: 100%;-webki=
t-text-size-adjust: 100%;">
=09<!--[if mso]>
=09=09=09=09<table align=3D"left" border=3D"0" cellspacing=3D"0" cellpaddi=
ng=3D"0" width=3D"100%" style=3D"width:100%;">
=09=09=09=09<tr>
=09=09=09=09<![endif]-->
=09=09=09
=09=09=09=09<!--[if mso]>
=09=09=09=09<td valign=3D"top" width=3D"600" style=3D"width:600px;">
=09=09=09=09<![endif]-->
<table align=3D"left" border=3D"0" cellpadding=3D"0" cells=
pacing=3D"0" style=3D"max-width: 100%;min-width: 100%;border-collapse: col=
lapse;mso-table-lspace: 0pt;mso-table-rspace: 0pt;-ms-text-size-adjust: 10=
0%;-webkit-text-size-adjust: 100%;float: left;" width=3D"100%" class=3D"mc=
nTextContentContainer">
<tbody><tr>
<td valign=3D"top" class=3D"mcnTextContent" style=
=3D"padding: 0px 18px 9px;color: #CCCCCC;mso-line-height-rule: exactly;-ms=
-text-size-adjust: 100%;-webkit-text-size-adjust: 100%;word-break: break-w=
ord;font-family: Helvetica;font-size: 16px;line-height: 150%;text-align: l=
eft;">
<p dir=3D"ltr" style=3D"color: #CCCCCC;margin:=
10px 0;padding: 0;mso-line-height-rule: exactly;-ms-text-size-adjust: 100=
%;-webkit-text-size-adjust: 100%;font-family: Helvetica;font-size: 16px;li=
ne-height: 150%;text-align: left;"><strong>Courses</strong><br>
Molds are often viewed as the heart of composites manufacturing=2C but the=
y are only one element of the tooling required to produce composite aerosp=
ace structures. As composite assemblies increase in complexity=2C addition=
al tooling such as assembly fixtures=2C trim tools=2C drill jigs=2C inspec=
tion gauges=2C and workholding become equally important for achieving repe=
atability and precision.<br>
<br>
The DarkAero Aerospace Mold and Tooling Course remains centered on the des=
ign and fabrication of composite molds while continuing to expand into add=
itional tooling concepts. Drawing from practical experience gained through=
both the DarkAero 1 program and contract manufacturing work=2C the course=
provides insight into the tooling strategies used to manufacture precisio=
n composite aerospace structures.<br>
<br>
The next session of the DarkAero Aerospace Mold and Tooling Course is sche=
duled for August 6=E2=80=937. Additional information and registration are=
available here:<br>
<br>
<a href=3D"https://us.list-manage.com/XSNeBSbp7G4?e=3Dcd183fa7a5&c2id=3Dd9e848cdbaa68931fa253ab5d1e9938c" target=3D"_blank" style=3D"mso-line-height-rule: exactly;-m=
s-text-size-adjust: 100%;-webkit-text-size-adjust: 100%;color: #007C89;fon=
t-weight: normal;text-decoration: underline;">Sign up for the August 6=E2=
=80=937 Session of the DarkAero Aerospace Mold and Tooling Course!</a></p>
</td>
</tr>
</tbody></table>
=09=09=09=09<!--[if mso]>
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=09=09=09=09<![endif]-->
</td>
</tr>
</tbody>
</table><table border=3D"0" cellpadding=3D"0" cellspacing=3D"0" width=3D"1=
00%" class=3D"mcnTextBlock" style=3D"min-width: 100%;border-collapse: coll=
apse;mso-table-lspace: 0pt;mso-table-rspace: 0pt;-ms-text-size-adjust: 100=
%;-webkit-text-size-adjust: 100%;">
<tbody class=3D"mcnTextBlockOuter">
<tr>
<td valign=3D"top" class=3D"mcnTextBlockInner" style=3D"paddin=
g-top: 9px;mso-line-height-rule: exactly;-ms-text-size-adjust: 100%;-webki=
t-text-size-adjust: 100%;">
=09<!--[if mso]>
=09=09=09=09<table align=3D"left" border=3D"0" cellspacing=3D"0" cellpaddi=
ng=3D"0" width=3D"100%" style=3D"width:100%;">
=09=09=09=09<tr>
=09=09=09=09<![endif]-->
=09=09=09
=09=09=09=09<!--[if mso]>
=09=09=09=09<td valign=3D"top" width=3D"600" style=3D"width:600px;">
=09=09=09=09<![endif]-->
<table align=3D"left" border=3D"0" cellpadding=3D"0" cells=
pacing=3D"0" style=3D"max-width: 100%;min-width: 100%;border-collapse: col=
lapse;mso-table-lspace: 0pt;mso-table-rspace: 0pt;-ms-text-size-adjust: 10=
0%;-webkit-text-size-adjust: 100%;float: left;" width=3D"100%" class=3D"mc=
nTextContentContainer">
<tbody><tr>
<td valign=3D"top" class=3D"mcnTextContent" style=
=3D"padding: 0px 18px 9px;color: #CCCCCC;mso-line-height-rule: exactly;-ms=
-text-size-adjust: 100%;-webkit-text-size-adjust: 100%;word-break: break-w=
ord;font-family: Helvetica;font-size: 16px;line-height: 150%;text-align: l=
eft;">
<p dir=3D"ltr" style=3D"color: #CCCCCC;margin:=
10px 0;padding: 0;mso-line-height-rule: exactly;-ms-text-size-adjust: 100=
%;-webkit-text-size-adjust: 100%;font-family: Helvetica;font-size: 16px;li=
ne-height: 150%;text-align: left;"><strong>DarkAero Capabilities</strong><=
br>
Composite manufacturing capability continued to expand with the addition o=
f a KR=C3=9CSS Mobile Surface Analyzer (MSA). The system provides quantita=
tive measurement of surface energy following surface preparation=2C allowi=
ng bond surfaces to be evaluated prior to adhesive bonding and secondary l=
amination. Surface energy is one of the primary metrics in determining the=
strength of a bond. Without any measurement of surface energy prior to bo=
nding=2C technicians must rely on more subjective=2C qualitative assessmen=
ts. Strict surface preparation procedures have already been established an=
d validated at DarkAero and are followed throughout bonding operations wit=
h specific quality checks. The MSA tool adds an extra layer of quality ass=
urance to verify that the surface preparation process is met and quantifia=
bly documented for each bonding operation. <br>
<br>
Build-out continued on the new facility expansion as well. Work completed=
included larger overhead doors=2C painting=2C and floor resurfacing. Rema=
ining work includes more lighting and additional drop power. Beyond increa=
sed manufacturing space=2C the expansion provides additional offices =
to accommodate the growing team. </p>
</td>
</tr>
</tbody></table>
=09=09=09=09<!--[if mso]>
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=09=09=09=09<![endif]-->
=09=09=09=09<!--[if mso]>
=09=09=09=09</tr>
=09=09=09=09</table>
=09=09=09=09<![endif]-->
</td>
</tr>
</tbody>
</table><table border=3D"0" cellpadding=3D"0" cellspacing=3D"0" width=3D"1=
00%" class=3D"mcnTextBlock" style=3D"min-width: 100%;border-collapse: coll=
apse;mso-table-lspace: 0pt;mso-table-rspace: 0pt;-ms-text-size-adjust: 100=
%;-webkit-text-size-adjust: 100%;">
<tbody class=3D"mcnTextBlockOuter">
<tr>
<td valign=3D"top" class=3D"mcnTextBlockInner" style=3D"paddin=
g-top: 9px;mso-line-height-rule: exactly;-ms-text-size-adjust: 100%;-webki=
t-text-size-adjust: 100%;">
=09<!--[if mso]>
=09=09=09=09<table align=3D"left" border=3D"0" cellspacing=3D"0" cellpaddi=
ng=3D"0" width=3D"100%" style=3D"width:100%;">
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=09=09=09=09<td valign=3D"top" width=3D"600" style=3D"width:600px;">
=09=09=09=09<![endif]-->
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pacing=3D"0" style=3D"max-width: 100%;min-width: 100%;border-collapse: col=
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<td valign=3D"top" class=3D"mcnTextContent" style=
=3D"padding: 0px 18px 9px;color: #CCCCCC;mso-line-height-rule: exactly;-ms=
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eft;">
<p dir=3D"ltr" style=3D"color: #CCCCCC;margin:=
10px 0;padding: 0;mso-line-height-rule: exactly;-ms-text-size-adjust: 100=
%;-webkit-text-size-adjust: 100%;font-family: Helvetica;font-size: 16px;li=
ne-height: 150%;text-align: left;"><strong>Looking Ahead</strong><br>
In August=2C the new facility expansion will be completed=2C making room f=
or larger CNC equipment and enabling more streamlined material flow in the=
shop. A new YouTube video will be released in August covering the proof l=
oad testing of the aileron system. Team growth will remain a major focus a=
s well. </p>
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ord;font-family: Helvetica;font-size: 16px;line-height: 150%;text-align: l=
eft;">
If you'd like to get more frequent updates on=
our progress and stay better connected with what we're up to=2C consider=
subscribing to our YouTube=2C Instagram=2C and LinkedIn accounts. Links t=
o these pages can be found below.<br>
<br>
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-rule: exactly;-ms-text-size-adjust: 100%;-webkit-text-size-adjust: 100%;c=
olor: #007C89;font-weight: normal;text-decoration: underline;">https://you=
tube.com/c/darkaeroinc</a><br>
Instagram: <a href=3D"https://us.list-manage.com/R9CmxYuvJ1l?e=3Dcd183fa7a5&c2id=3Dd9e848cdbaa68931fa253ab5d1e9938c" target=3D"_blank" style=3D"mso-line-height-rule:=
exactly;-ms-text-size-adjust: 100%;-webkit-text-size-adjust: 100%;color:=
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m.com/darkaeroinc</a><br>
LinkedIn: <a href=3D"https://us.list-manage.com/T5V_n81bwj8?e=3Dcd183fa7a5&c2id=3Dd9e848cdbaa68931fa253ab5d1e9938c" target=3D"_blank" style=3D"mso-line-height-rule:=
exactly;-ms-text-size-adjust: 100%;-webkit-text-size-adjust: 100%;color:=
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X: <a href=3D"https://us.list-manage.com/Io_Omzp6Zje?e=3Dcd183fa7a5&c2id=
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y;-ms-text-size-adjust: 100%;-webkit-text-size-adjust: 100%;color: #007C89=
;font-weight: normal;text-decoration: underline;">https://x.com/darkaeroin=
c</a>
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<td valign=3D"top" class=3D"mcnTextContent" style=
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tica;font-size: 12px;line-height: 150%;text-align: center;">
<span style=3D"font-size:10px"><span style=3D"=
color:#808080"><em>Copyright =C2=A9 2026 DARKAERO=2C INC=2C All rights res=
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You are receiving this email because you opted in at our website. If you=
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mily: Helvetica;font-size: 12px;line-height: 150%;text-align: center;"><sp=
an style=3D"color:#808080; font-size:8px">DARKAERO=2C INC
6448 Ronald Reagan Ave
MADISON=2C WISCONSIN 53704
USA</span></p>
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xt-size-adjust: 100%;-webkit-text-size-adjust: 100%;color: #FFFFFF;font-fa=
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