Bold claim: a record-setting fuselage milestone shows what happens when software-driven manufacturing meets aerospace ambition. Divergent Technologies and Saab have delivered the first set of fuselages for Saab’s future autonomous aircraft concept, produced without custom tooling or fixtures. Instead, the work relied on Divergent’s fully digital, software-defined manufacturing approach, the Divergent Adaptive Production System (DAPS™), which integrates AI-informed design, high-rate additive manufacturing, and robotic assembly to shorten development time, boost performance, and reduce costs compared to traditional methods.
The completed fuselage was a joint design and build effort between Saab and Divergent. It represents one of the largest laser powder bed fusion (LPBF) structures ever flown, underscoring the project’s technical significance and the growing capability of fixtureless assembly to handle demanding aerospace applications. The full assembly measures 15 feet long and comprises 26 uniquely printed parts, all joined and bonded within Divergent’s robotic, fixtureless production cell.
Lukas Czinger, Co-founder and CEO of Divergent, noted, “This Saab collaboration demonstrates what’s possible when ambitious aircraft concepts are paired with a complete, software-defined manufacturing platform. By tightly weaving digital design, additive manufacturing, and automated assembly, we delivered a large-scale fuselage structure that aligns with Saab’s vision and delivers speed, flexibility, and integrated performance that traditional approaches can’t match.”
Axel Bååthe, head of Saab’s Rainforest, added, “Using Divergent’s additively manufactured and digitally designed structures gave our joint team unprecedented flexibility in this development. Digital design and advanced manufacturing are key enablers for our ongoing collaboration and success in this project.”
About Divergent: Divergent has created the world’s first end-to-end software-hardware production system for industrial digital manufacturing—the Divergent Adaptive Production System (DAPS™). This platform enables customers to design, additively manufacture, and automatically assemble complex structures for automotive, aerospace, and defense applications. DAPS redefines the economics, speed, and scalability of defense vehicle manufacturing by optimizing designs, dematerializing structures, and eliminating upfront capital expenditure. More information is available at Divergent’s website.
About Saab: Saab is a global defense and security company focused on helping nations keep their people safe. With 27,000 employees and a broad technology base, Saab designs, manufactures, and maintains advanced systems across aeronautics, weapons, command and control, sensors, and underwater domains. Saab operates internationally from Sweden and serves as a major part of several nations’ domestic defense capabilities.
The Rainforest: Saab’s internal innovation initiative dedicated to transformative projects. Learn more at The Rainforest’s website.
Source: Divergent Technologies, Inc.
