World's first hypersonic vehicle with a fully 3D-printed airframe passes key tests for Mach 7 speed
Published on Feb 12, 2026 at 8:59 AM (UTC+4)
by Molly Davidson
Last updated on Feb 12, 2026 at 8:59 AM (UTC+4)
Edited by
Molly Davidson
A company in Australia just shook its hypersonic vehicle on purpose.
Not because something went wrong.
But because if you want to fly at Mach 7, you’d better make sure nothing rattles off first.
And this one is special, because the entire airframe was 3D-printed.
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This fully 3D-printed hypersonic vehicle just survived a serious stress test
Queensland-based Hypersonix Launch Systems says its DART AE has passed vibration testing, which is basically the engineering version of putting something in a giant mechanical washing machine.
Engineers shake the vehicle to copy the intense forces it would feel during launch and high-speed flight.
If a bolt is loose or a panel can’t handle the stress, this test exposes it.
The DART AE survived.
That’s a big deal, because this is the world’s first hypersonic vehicle with a fully 3D-printed airframe made from high-temperature metal alloys.
Instead of building it the old-school way, they used additive manufacturing – layering metal bit by bit until the structure was complete.
It’s about 10 feet long (3m), weighs roughly 660 pounds (300kg), and it’s designed to hit Mach 7.
For context, hypersonic starts at Mach 5.
Mach 7 means seven times the speed of sound.
At that speed, you could cross entire countries in minutes.
Power comes from a hydrogen-fueled scramjet engine.
That’s a special type of jet designed to work at ridiculous speeds where normal engines simply wouldn’t cope.
The company claims the vehicle could travel up to 621 miles (1,000km).
Passing vibration testing doesn’t mean it’s flown yet.
It just means the structure can handle the punishment.
Next up are integration and pre-flight checks before it ever leaves the ground.
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Why everyone suddenly cares about Mach 7
Hypersonic vehicles are getting attention because of how fast they are.
Really fast.
Anything above Mach 5 moves so quickly that current defense systems struggle to respond in time.
That’s why countries are investing heavily in scramjet-powered tech and glide vehicles.
In this case, Hypersonix also built and designed the DART AE entirely in Australia, using advanced 3D printing methods that fit with the country’s manufacturing goals.
We've successfully completed vibration testing of our DART AE, verifying component reliability and structural integrity for hypersonic flight!
— Hypersonix Launch Systems (@HypersonixAU) February 9, 2026
The assesment validate's that DART’s materials can withstand the intense mechanical stresses of high-speed performance. Another… pic.twitter.com/eQTFZOknRw
The DART AE hasn’t taken off yet.
But if it can survive being shaken like that and still hold together, Mach 7 is starting to sound less like science fiction and more like a countdown.
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With roles at TEXT Journal, Bowen Street Press, Onya Magazine, and Swine Magazine on her CV, Molly joined Supercar Blondie in June 2025 as a Junior Content Writer. Having experience across copyediting, proofreading, reference checking, and production, she brings accuracy, clarity, and audience focus to her stories spanning automotive, tech, and lifestyle news.
