FAQ

BASIC QUESTIONS

What is the DarkAero 1?
The DarkAero 1 is a two-seat kit aircraft engineered specifically for high speed, long range flight. The airplane is optimized to fly cross country missions efficiently. It was designed using modern engineering tools and is built from carbon fiber and aerospace alloys.
Can I purchase a complete, ready-to-fly DarkAero 1?
The DarkAero 1 is designed, manufactured, and sold specifically as a kit aircraft. While we do not offer the kit for sale yet, we do allow interested customers to reserve a production slot for a kit when we enter production.
Can you provide more information on reserving a kit?
Customers can reserve a production slot for a DarkAero 1 kit by filling out a simple reservation agreement form and paying a refundable deposit. Reserving a kit allows us to get a more accurate projection of demand so we can better plan for scaling up manufacturing in future production.
How much will the kit cost?
The estimated complete flying cost of the aircraft is around $200k. The builder's selection of avionics, propeller, engine accessories, and paint affect the total cost.
What does the kit include?
The Kit Includes:
Carbon Fiber Airframe
Canopy
Engine Mount
Landing Gear
Control Hardware
Fittings and Fasteners
Kit Plans
Purchased Separately:
UL Power 520iS Engine
Avionics and Electrical Hardware
Propeller
Wheels and Brakes
Paint
Is it difficult to build a DarkAero 1? How long will it take?
The DarkAero 1 is sold as a quickbuild kit, requiring no messy or complicated layups, jigs, molds, hand carving, or shaping work traditionally found with composite kit aircraft. We have eliminated much of the tedious sanding work that is typically required to complete a composite kitplane. The aircraft is designed to be fabricated and assembled using basic tools, most of which can be purchased at your local hardware store. We are estimating a build time similar to other quickbuild kits at around 1,000 to 1,500 man-hours. Individual build times will vary depending on your schedule, skills, and prior hands-on experience. More insight into the DarkAero 1 build process can be found here: Builder Resources
Will you offer a builder assist program?
Given that the kit is quickbuild standard, we are intending for the build to be as straightforward and intuitive as possible. It will not require a significant learning curve or expensive/complicated tools. The builder can feel comfortable knowing that all precision and complicated carbon fiber work has already been done by the DarkAero team. That said, we have had a number of people express interest in a builder assist program for the DarkAero 1, and it is something we are considering.
Does the kit include a ballistic parachute?
We do not have a BRS parachute incorporated in the prototype, but it is something we are exploring as a potential option for kits.

TIMELINE

When will you complete the DarkAero 1 prototype, and when will you begin producing kits?
Initial taxi testing of the DarkAero 1 has already begun, and flight testing is targeted to commence in 2024. Production of the first customer kits will follow the completion of flight testing. We anticipate a gradual ramp into production since there will be initial inefficiencies in scaling up manufacturing and growing our team.
What is your biggest challenge?
It’s relatively easy to crank out a one-off prototype, it’s an entirely different challenge to create a design that is manufacturable at scale and safe for a broad audience. Even though we call it a prototype, the aircraft we are working on is representative of what customers will see in their kits. Most of our time and effort goes into testing, design reviews, and iterating on design concepts to improve safety and manufacturability. We can generate designs quickly, but we often spend much more time working out design improvements to make things more suitable for customers.
Can I come visit DarkAero?
We love to share as much as possible about the development of the DarkAero 1, but in general, we are unable to accommodate visitors. DarkAero has grown in public visibility, and we now receive daily requests for shop visits and tours. Fulfilling all these requests would be a major distraction from the project, and we want to remain focused on our goal of completing the prototype DarkAero 1. Given our tight timeline, we have limited shop visitors to those essential to the project such as test pilots, suppliers, technical counselors, etc. Staying focused on bringing the DarkAero 1 to completion is the best way for us to serve our customers and the aviation community. We recognize that it is not the same as an in-person visit, but we do have over 100 videos on the DarkAero YouTube Channel that give a window into the aircraft development and life in the shop.

ENGINE

Why did you select the UL Power UL520iS engine for the DarkAero 1?
We chose the 200 HP UL520iS because it has an excellent power to weight ratio. For comparison, the UL520iS is 50-70 lbs lighter than traditional aircraft engines at the same horsepower. The engine also has a number of modern features like FADEC, which help reduce pilot workload. For more details on the UL Power UL520iS visit http://ulpower.com/en/engines/ul520.
Is this engine proven?
UL Power has been around for over 15 years and has sales and service in 20 countries worldwide. They have thousands of engines in experimental category, military, and UAV applications. They are approaching ASTM certification on their engines so their designs are well refined at this point.
What is the TBO (time before overhaul)?
The current TBO is 1,500 hours.
What propeller will work for the UL520iS engine?
The prototype DarkAero 1 is equipped with an electrically actuated constant speed propeller made by Airmaster Propeller. This propeller is specifically set up to work with the UL520iS engine and is optimized for high speed flight.
Are you working on a turbocharged option for the DarkAero 1?
We are keeping an eye on the turbo version of the UL520iS and have considered what modifications would be required to the DarkAero 1 to adopt it. For now, we are remaining focused on integrating the stock version of the engine.
Can I use a different engine in the DarkAero 1?
The airframe of the DarkAero 1 was designed and optimized around the UL520iS engine. Selecting a different engine will likely yield poorer performance than a stock configuration and will increase the project cost and build time.

AIRFRAME

How are your carbon fiber parts manufactured?
All of our carbon fiber parts are made using a process called infusion. This process involves placing dry carbon fiber cloth into a mold, compressing it under a vacuum bag, and then infusing it with epoxy resin. This method offers several benefits including repeatability, tight process control, excellent surface finish, and high fiber to resin ratio.
Why don’t you use pre-preg carbon fiber and cure it in an autoclave?
We are able to achieve similar results to prepreg autoclave with the infusion process but with much lower overhead.
How are your carbon fiber parts cured?
The carbon fiber airframe structures in the DarkAero 1 are cured in a computer controlled oven. The oven follows an optimized cure schedule for our materials that we developed with the help of the Polymer Engineering Center at the University of Wisconsin - Madison. Sensors in the oven collect and record temperature measurements throughout the oven volume during the entire cure cycle to ensure our parts are cured to specification.
How do you know everything is bonded together?
Every internal rib, shear web, and bulkhead in the airframe is CNC cut. The external skins of the airframe are molded on CNC formed tooling. All these components are trial fit together using CNC cut assembly jigs to ensure proper alignment before the final bonding operation. We also employ non-destructive tests after assembly as a secondary measure of bond quality.
How do I repair the carbon fiber if it gets damaged?
As with all aircraft, any damage to your plane should be evaluated on a case by case basis. If minor damage does occur in non-structural areas, it can be inspected and repaired in compliance with FAA guidelines. In the worst case where severe damage occurs to a part, the entire section may need to be replaced.

PERFORMANCE

Will the DarkAero 1 achieve its predicted performance numbers?
The performance numbers on our website are calculated projections, and of course, need to be proven in flight testing. Many variables feed into these projections including performance data from the engine and propeller manufacturers, aerodynamic coefficients from CFD and wind tunnel testing, and other parameters including cooling drag and interference drag. Our performance targets are certainly bold but by no means physically impossible. One of the primary ways we have tried to squeeze out more performance is through keeping the airplane light. Minimizing weight on any airplane turns into a virtuous cycle. A lighter airplane requires less wing area to achieve flight which means less drag. Less drag means we can fly at higher speeds without increasing the size of the engine. Keeping the engine small means lower fuel consumption, which results in more range for a given fuel volume. Naturally, there are limits to what can be achieved under this approach, and the DarkAero 1 represents an effort to explore those limits.
Can I fly aerobatics in the DarkAero 1?
No. The DarkAero 1 was specifically designed and optimized for high speed, long range flight. Every aircraft design requires compromises, and adding the capability to fly aerobatic maneuvers would have detracted from our aircraft’s speed, range, and efficiency. The airframe of the DarkAero 1 is structurally and aerodynamically designed to fly normal category maneuvers only. If we intended the DarkAero 1 to be an aerobatic airplane, we would have designed it differently.
Can I fly the DarkAero 1 from my grass strip?
The DarkAero 1 is primarily intended for operations from paved runways. It is not a STOL aircraft. We still have to confirm performance numbers through flight testing, but based on calculated numbers we would recommend a runway of at least 3000ft. The takeoff and landing roll is calculated to be around 1000 ft at sea level. It is important to operate from runways longer than this to provide a safety margin for rejected takeoffs or overshoots on landing.
Can I modify the DarkAero 1?
That depends on what the modification is. Since the DarkAero 1 is a kit that you build, you have the freedom to make the airplane your own. There are many things to customize to your taste including the avionics, paint, and interior. Larger modifications to the structures, aerodynamics, and systems are not recommended because they require thorough engineering effort to validate and implement safely. If your intent is to modify the airplane to alter the aircraft performance and capability, consider whether there is a better aircraft to fit your mission that does not require major modifications.

ABOUT DARKAERO

Where is DarkAero located?
DarkAero is headquartered in Madison, WI.
Can I come work for DarkAero?
Yes! We are soon transitioning into production and are looking for machinists, composite technicians, and mechanics. If you have good hands-on skills and attention to detail, we would like to hear from you! You can submit a resume and cover letter to careers@darkaero.com



If there is anything we failed to address in this FAQ, feel free to reach out to us at info@darkaero.com.