The blended-wing-body (BWB) aircraft design from JetZero not only offers 30% improved aerodynamic efficiency but could also reduce maintenance time by 30%, as reported at the MRO Americas conference, according to AviationWeek.
The California-based startup, in collaboration with Siemens, has developed a digital engineering approach that incorporates fiber-optic sensors embedded throughout the aircraft’s structure. This predictive maintenance system enables real-time monitoring of structural and system conditions, replacing traditional scheduled inspections.
“By developing the aircraft in a digital environment, our goal is to reduce maintenance time by 30%,” said Sonny Stern, Head of Customer Support for JetZero. “Today’s technology finally makes condition-based maintenance truly viable.”
The company is currently developing a BWB demonstrator under a $235 million contract with the U.S. Air Force, with its first flight planned for 2027. Northrop Grumman’s Scaled Composites is assisting in the prototype’s construction. JetZero anticipates the platform will evolve into both a military tanker and a commercial airliner for 250-260 passengers by 2030-31.
Commercial airlines are already showing strong interest. Delta Air Lines committed in March to playing a “key role” in the aircraft’s development, particularly in cabin design, highlighting the “endless possibilities” the BWB design offers for passenger experience. Alaska Airlines has also expressed serious interest in the platform.
Although condition-based maintenance concepts have already been attempted on conventional aircraft like the Airbus A350 and Boeing 787, Stern believes today’s sensors and data analytics capabilities make this approach more cost-effective. The BWB’s integrated structure may be particularly well-suited for this maintenance philosophy, thanks to its composite construction and lack of traditional structural joints.
The maintenance improvements would further enhance the estimated fuel savings from the aircraft’s aerodynamic profile. JetZero claims the design reduces drag by at least 30% compared to conventional aircraft. Aviation experts note that if successful, JetZero’s approach could revolutionize both aircraft operations and maintenance practices. However, they caution that certifying both the novel airframe and its maintenance philosophy will present significant regulatory challenges.
