Composites and Code: Aurora Backs MQ-25A First Flight

From manufacturing tough parts to developing smart software, Aurora Flight Sciences is proud to support the MQ-25A Stingray^™.

On April 25th, the U.S. Navy’s first MQ-25A Stingray^™, an unmanned aerial refueler, successfully completed its first flight. Boeing subsidiary Aurora Flight Sciences played a significant role by providing manufacturing and engineering expertise that helped solidify the aircraft’s readiness for this historic milestone.

Delivering Components That Withstand Challenging Environments

At its facilities in Mississippi and West Virginia, Aurora produced 145 components and assemblies for the flight test aircraft. This work included nearly the entire exterior surface of the aircraft, which is made up of lightweight, high-strength composite skins designed to withstand the harsh, corrosive conditions of carrier-based operations. Some components, including the tail stabilators, fuselage edges, and engine inlet, were also designed and analyzed by Aurora engineers in Virginia.

Across multiple MQ-25A builds, Aurora has delivered over 1,100 components and assemblies in total so far. Aurora’s Mississippi team delivers the majority of the pieces including fuselage skins, door assemblies, and wing parts; while West Virginia supplies the aircraft’s complete tail assembly, as well as airframe, fuselage, and wing parts.

Advancing Software for Reliable Autonomous Operation

Aurora supported flight software development by embedding its software and autonomy engineers directly into a unified Boeing team. The MQ-25A is an autonomous aircraft that responds to commands from Air Vehicle Pilots in the Unmanned Carrier Aviation Mission Control System MD-5 Ground Control Station (GCS), enabling the aircraft to taxi, take off, fly and land autonomously.

Aurora engineers enhanced Guidance, Navigation, and Control (GNC) systems, streamlined software-directed mission procedures, and validated the software’s response to demanding operational environments. This work improves aircraft safety and reliability through changing conditions and operations such as wind, turbulence, ship-relative maneuvers, and catapult launches.

Expanding Capabilities for the US Navy

As the Navy’s first operational carrier-based unmanned aircraft, the MQ-25A Stingray will extend the reach of the carrier air wing through unmanned aerial refueling and manned-unmanned teaming. Aurora is proud to help deliver the cutting-edge technologies that make this capability possible—and to support the future of naval aviation.