Re:Build Manufacturing, a leader in high-performance engineering and advanced manufacturing for the aerospace and defense sectors, announced its selection by Otto Aviation to design and manufacture the structural control surfaces for the company s Phantom 3500 aircraft.

The Phantom 3500, featuring a distinctive laminar flow fuselage and high-aspect-ratio wing, is engineered for ultra-efficient flight. The aircraft is designed to burn 60% less fuel than competing super-midsize jets, with potential emissions reductions of up to 90% when operated with sustainable aviation fuel (SAF). Achieving this performance requires precision-tooled, tight-tolerance control surfaces that minimize aerodynamic drag an area where Re:Build s expertise will be critical.

Re:Build is collaborating closely with Otto s engineering team to ensure the control surfaces meet structural requirements while leveraging advanced tooling and composite manufacturing strategies. The all-composite Phantom 3500 airframe requires tight-tolerance structural interfaces at the wing and empennage, making the integration of these surfaces vital to the aircraft s laminar flow concept.

Our goal is to engage with customers and products at the forefront of high-impact industries, where we can simultaneously solve for quality, timeliness, and cost, said Miles Arnone, co-founder and CEO of Re:Build Manufacturing. Collaborating with Otto on their laminar flow design reflects the level of engineering rigor and manufacturing quality required to advance the American aerospace ecosystem.

Re:Build will bring its aerospace structural design, analysis, and thermoset composite manufacturing expertise to the Phantom 3500 program, supporting the development of initial pre-production airframes and scaling production as the aircraft moves from certification toward entry into service.

The Phantom 3500 is expected to begin flight testing in 2027, with entry into service targeted for 2030.

Source: rebuildmanufacturing.com