Dawn Aerospace, manufacturer of the Mk-II Aurora, announced that New Zealand’s Civil Aviation Authority (CAA) has granted it approval to fly at “unlimited” speeds at up to 80,000 feet in altitude. The company is permitted to fly beyond the visual line of sight (BVLOS) of a remote pilot and will not be limited to restricted airspace.

Dawn describes the Aurora as “an aircraft with the performance of a rocket.” According to the company, the aircraft is designed to be the first vehicle capable of flying to the Kármán line—which at about 100 kilometers in altitude is considered the edge of space—twice in one day.

“This unlocks the next major performance milestone for the Mk-II vehicle, namely supersonic flight,” said Stefan Powell, CEO of Dawn. “To the best of our knowledge, this would be the first privately funded [uncrewed aerial vehicle] to break the sound barrier.”

The only successful supersonic airliner, Concorde, which was developed by two now-defunct manufacturers, was retired more than two decades ago. But a new crop of companies, including Dawn and Boom Supersonic, are trying to break the sound barrier again.

Unlike Boom’s Overture, which is being developed as a passenger airline, Dawn’s Aurora is intended for space transportation.

The Mk-II first flew in 2021 and has since completed more than 50 test flights, operating under both jet and rocket power. It last flew in 2023, reaching 200 knots at an altitude of 9,000 feet. But those flights were under a more restrictive license than the one obtained by the company last week.

The goal of the firm’s upcoming campaign, which will comprise about a dozen flights between July and September, is to reach Mach 1.1—the boundary of supersonic speed—at an altitude of 70,000 feet. It hopes to fly to space twice in one day and spend about 180 seconds in microgravity.

If it achieves all objectives, the company believes it would set records for speed, altitude, and climb rate for a self-powered aircraft.

Dawn’s primary business is manufacturing propulsion systems for satellites, and it has 76 thrusters in space. But the company is now looking to enter the suborbital space.

The Aurora is a first-stage demonstrator for the company’s more robust Mk-III—a two-stage-to-orbit model that will take off from the runway and deploy a 250 kilogram satellite at the apex of its flight path.

According to Dawn, it is remotely piloted, low cost, and “rapidly reusable,” designed to fly multiple times per day and between 100 and 1,000 times over its lifespan.

Its engine uses storable, “aircraft friendly” propellants that allow the vehicle to take off without having to wait to be fueled. The engine is also carbon neutral, producing no hydrocarbons during operation.

“Room temperature storable propellants will not boil off, and carbon fiber will not suffer from microcracking, as is common in cryogenic composite tanks,” the company says on its website.

Dawn chose a winged design in order to reduce the risk of an engine malfunction, which could jeopardize the landing—and therefore reusability—of the Mk-II. It will be certified as an aircraft in New Zealand. The model takes off like a conventional aircraft, accelerating to Mach 3 speeds and bending upward into a near-vertical route. On the way down, it descends and glides horizontally back to the runway.

Dawn’s first phase of aircraft testing, conducted with the company’s jet-powered Mk-I, comprised eight hours of flight time across 47 flights. After receiving CAA approval for rocket-powered flight in March 2023, it began flying in just a few weeks.

So far, the Mk-II has made three rocket-powered flights, completed within a three-day span a little over one year ago, as part of the second phase of aircraft development, with the goal of reaching the Kármán line under certification.

According to a blog post from Powell, the current version of the vehicle has a maximum altitude of about 60,000 feet, which will require the company to develop a more powerful variant called the Mk-IIB.

“At full performance, the Mk-II will fly faster and 2.5 times higher than any prior aircraft that takes off from a runway, including the current record holder, the SR-71 Blackbird,” said Powell. “That is the power of bringing rocket performance to an aircraft platform.”

Despite being a demonstrator, Dawn plans to one day use the aircraft for Earth observation, high-speed flight research, in-space science including microgravity research, and even civil and defense applications. According to Powell, the company is already fielding interest in a commercial version of the Mk-II and will be in a “prime position” to roll one out once it reaches the Kármán Line.

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Well, that obviously didn’t happen. The pandemic blew up everyone’s plans, and given the obvious jeopardy to my livelihood, the loss of our adventure barely registered. And then, as the world began to open back up, New Zealand stayed locked down longer than most. It wasn’t until Oshkosh 2022, when Dawn and I ran into Matt and Jo McCaughan at the FlyInn booth, that we dusted off our travel plans.

The McCaughans are friendly Kiwi sheep and cattle ranchers hailing from central Otago on the South Island, where they also run FlyInn, billed as “the authentic NZ self fly vacation.” They are also avid cruising sailors, which quickly became our main topic of conversation. Almost as an afterthought, we told them that while we’d be busy building our hangar/apartment for the 2022-23 season, we’d come fly with them in December 2023. Our revived New Zealand adventure would be our 20th wedding anniversary gift to each other.

We flew my airline from Seattle to Auckland on November 15, staying in New Zealand’s largest city for several days. On the 19th, our good friends Brad and Amber Phillips flew in, whereupon we rented a pair of campervans and headed south. The next two weeks would have been a pretty great vacation on their own. We spent six more days on the North Island, visiting the usual “must-dos” like Rotorua, Tongariro National Park, and Wellington as well as many more out-of-the-way locales.

Crossing the Cook Strait on a typically raucous ferry ride following a 40-knot blow, we spent another eight days road tripping through the South Island. We sampled excellent wine in Marlborough, tramped the fantastic coastal trail in Abel Tasman National Park, got rained on all down the wild West Coast, and set up camp in truly epic surroundings at Aoraki/Mount Cook National Park. All throughout, both the landscapes and climate frequently reminded us of the Pacific Northwest, Idaho, and Montana.

• READ MORE: Pilot Mental Health Remains the Last Taboo in Aviation

The roads were scenic and engaging, the locals exceptionally friendly and helpful, the cities few and far in between. This is a country slightly larger than the U.K. but with only 5 million people…and 75 million sheep.

In Christchurch we returned the campers and said goodbye to the Phillips, as their busy life back home precluded them from joining the flying tour—more’s the pity. Dawn and I took an Air New Zealand ATR-72 from Christchurch to Queenstown, New Zealand’s renown adventure tourism hot spot, which is where the FlyInn tour began the next day.

Soon after we landed, Jo McCaughan emailed to say that they were rejiggering the itinerary to go to Milford Sound and Fiordland on day one, thanks to a brief weather window. This made sense. All throughout our travels, the weather had been exceptionally variable, with low ceilings and pouring rain as well as bright sunshine being encountered more days than not. It was clear that flying in New Zealand requires a fair amount of flexibility. Still, from what little I knew of Milford Sound, I got the impression that I was being thrown right into the deep end, sink or swim.

At the airport the next morning, we were joined by Matt McCaughan, longtime FlyInn instructor Nick Taylor, and North Carolinian couple Adam and Lissa Broome, our counterparts for the next eight days. McCaughan and Taylor introduced us to our rides for the week, two 180 hp Cessna 172s, registrations ZK-TRS and ZK-WAX.

For safety purposes FlyInn tends to keep the airplanes together, so we got to know the Broomes over the course of the tour. Notably, Adam circumnavigated the globe with his Beech Bonanza in 2016, making for some very interesting stories.

Dawn and I drew the eye-catching, yellow-and-blue ZK-WAX for the week and started with Matt as instructor. We began with a short hop up to Wanaka, FlyInn’s base of operations, for a coffee and chat. Sufficiently briefed, we departed to the northwest over the serrated, deep-blue ribbon of Lake Wanaka and climbed to circle striking, glacier-draped Mount Aspiring, “The Matterhorn of the South.”

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Beyond its peak, the weather turned significantly cloudier than forecast—no big surprise there. We flew over the top for a bit, found a good hole, dropped into a wide, verdant valley, and followed the glacial, gravel-strewn Pyke River to the appropriately named Big Bay. After making a good inspection pass and landing on the broad, dark-sand beach, we went for a tramp a short way inland, where there’s a hiker’s hut and seasonal fish camp. This is a good week’s hardy walk from the nearest road, and all resupply is done via beach landing.

We soon departed over the crashing surf and turned out to sea, making our way south around a series of cloud-choked headlands. Matt duly noted St. Anne’s Point straight ahead, and then Dale Point to our left, our cue to turn into the rain-soaked entrance to world-famous Milford Sound. It looked VFR—only just. Matt noted there would likely be sunshine (albeit with a lot of wind) at the head of the fjord. I proceeded in, keeping my right wing hard against the northern wall of the gorge at Matt’s urging—the better to turn around if his promised good weather didn’t materialize. But it did, along with rainbows and a couple dozen waterfalls and steaming tourist cruise boats. It was a truly magnificent sight.

And then came the wind, streaking the head of the fjord with long ribbons of spume and giving our little 172 a good bashing. Unperturbed, Matt kept up his litany of mandatory radio position reports. I was glad he was there since it was challenging enough just flying. I turned up the Cleddau River valley and began my letdown, reversing course at a wide fork in the river to make a modified dogleg final to Runway 29 at Milford Sound Airport (NZMF).

The sea breeze was gusting at 30 knots. My landing was not pretty. It was safe and acceptable, that’s all. A short taxi later, we shut down in the shadow of a dozen tour operators’ Grand Caravans, Airvans, and Kodiaks. With the steep rock walls and silvery cascades of Milford Sound as a majestic background, it would’ve made the world’s best “Learn to Fly!” poster.

As we ate lunch, I reflected on a few things. First, Kiwi pilots appear to be pretty comfortable in marginal VFR (IFR not being very common here). Strong local knowledge of weather and terrain helps mitigate the risk, as does observing a few rules of thumb that closely mirror those that my old-school first CFI taught me as “the right way to scud-run.”

Second, there’s a lot of trust in the engine—though, admittedly, a lot of the valley floors are probably survivable in case of forced landing, with fairly stunted bush and plentiful gravel bars on the rivers.

Thirdly, the high density of world-class scenery coupled with a highly developed tourist industry make much of the New Zealand backcountry far more air-trafficked than comparable sites in the U.S., with accordingly more rigid procedures despite a relative lack of ATC facilities.

This would be a tough place for the uninitiated to go it alone—thus the appeal of an operation like FlyInn.

Departing into the maelstrom once more, we climbed over Milford Sound and ducked into the relative calm of the Arthur River valley. This impossibly scenic, waterfall-laced, glacier-carved hanging valley, traversed by the famed Milford Track, perfectly frames the 2,000-foot cascade at its head, Sutherland Falls, once thought to be the world’s tallest. It pours from what appeared to be a neat rock-walled thimble of a tarn, Lake Quill.

“Want to fly around it?” asked Matt with a wry grin. He knew I’d think this was a crazy idea, and at first glance I did. “There’s more room than it looks,” Matt said. “Just put out 20 degrees of flaps and slow to 65 knots.”

So I did, and it was absolutely spectacular, one of the neatest things I’ve done in an airplane. Once we completed our circuit, we dove out of the thimble and ZK-TRS buzzed in, and as I watched them my perspective suddenly shifted, revealing the epic scale of the landscape we were exploring. The effect was magical.

I’ve described the memorable first two hours of a weeklong tour in New Zealand, and I think everything we saw could fill a year’s worth of columns. I’ll content myself with two, cramming the balance into next month’s contribution. In the meantime, by the time you read this, my special V1 Rotate video episode, “New Zealand By Air,” should be live on FLYING’s website.

We recorded some 500 gigabytes of footage, much of it spectacular, and editing it down to 15 minutes proved to be a real challenge. There are worse problems to have.

This column first appeared in the March 2024/Issue 946 of FLYING’s print edition.

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The company on Wednesday announced it completed the build of its Certification System Bench, a flight test simulator designed to speed its path to an STC. The simulator contains the company’s certifiable software and hardware components and is located at its Boston headquarters.

An STC is issued by a regulator when a company intends to modify an aerospace product from its initial, type-certified design. The approval authorizes the modification and how it will affect the original product.

In the case of Merlin, the company is seeking an STC from New Zealand’s Civil Aviation Authority (CAA) for Merlin Pilot, its platform-agnostic, takeoff-to-touchdown autonomy system for fixed-wing aircraft. Pilot uses an array of sensors to understand the state of the aircraft and its surroundings. The firm is working toward concurrent validation with the FAA through a Bilateral Aviation Safety Agreement between it and the CAA.

However, Merlin’s goal, at least in the short term, is not to remove the pilot from the cockpit entirely. Rather, it intends to supplement pilot workloads to combat the ongoing pilot shortage.

“In many ways, the Certification System Bench acts as a testing ‘funnel,’” said Sherif Ali, chief engineer for Merlin Pilot. “It allows us to test hundreds of cases with speed and ease, selecting edge cases to take to in-flight testing. As a result, we’re able to reduce the use of our test aircraft and keep it for limited cases only.”

The Certification System Bench will allow Merlin to test its automation systems from its headquarters, with no limitations due to factors such as weather, maintenance schedules, or pilot availability. The company says it provides a one-to-one replica of its in-flight technology, with three screens representing the pilot deck, instrument panels, and primary flight display.

The technology is equipped with the same software and hardware components found within the Pilot system. Further, cameras installed on the Bench allow Merlin’s global team to access it and perform testing remotely.

“With pilots on the Certification System Bench, we are able to learn multitudes about human factors while gaining accreditation towards our STC,” said Ali. “No other company in the sector has put more resources towards this type of testing simulator.”

According to Merlin, the Certification System Bench represents a “significant investment” for the firm—costing millions of dollars more than its actual aircraft—but one that will be worthwhile.

The company says ground tests on the Certification System Bench are accredited by aviation regulators, allowing those evaluations to contribute toward STC approval. Further, the technology should allow testing to become more routine. Technicians won’t need to worry about heavy rain or malfunctioning aircraft parts.

“Ensuring the Merlin Pilot is robust, safe, and reliable is our top priority, which underscores this [Certification] System Bench build as a huge milestone in Merlin’s certification journey,” said Matt George, founder and CEO of Merlin. “It took the team six months to design, vet solutions for, and build the Certification System Bench to extremely stringent specifications.”

Merlin is taking a “crawl-walk-run” approach to certification and operations, beginning with testing with the FAA and CAA, from which it recently obtained Part 135 operator approval. The next step will be to fly small aircraft with reduced crews, relying mostly on Pilot but augmented by a safety pilot. After that, the company intends to remove crews from small aircraft and reduce crews on larger aircraft.

Merlin received the first certification basis for an autonomous flight system from the CAA in 2023. Last year, Pilot also became the first autonomy system to secure U.S. National Airspace System integration and FAA validation, following agency-contracted uncrewed cargo network trials in Alaska, the company says.

Pilot so far has been integrated on five different aircraft types, including Dynamic Aviation’s fleet of Beechcraft King Airs and several aircraft from Ameriflight, the largest Part 135 cargo airline in the U.S.

Merlin further has a longstanding relationship with the U.S. Air Force, through which it has modified several military transport aircraft. In 2022, the company tested single-pilot crews aboard a Lockheed Martin C130J Hercules and conducted an autonomous refueling mission using a KC-46A Pegasus with no copilot.

In February, the partners extended their collaboration to demonstrate Pilot on a KC-135 Stratotanker. Merlin expects in-flight trials to begin next year, starting with a series of basic air refueling operations.

However, Merlin is not the only autonomous flight systems partner working with the Air Force. The department also has relationships with providers such as Xwing, Reliable Robotics, and rotorcraft manufacturer Sikorsky, which is developing an autonomy suite called Matrix.

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Boston-based Merlin Labs—the maker of a platform-agnostic, takeoff-to-touchdown autonomy system for fixed-wing aircraft—on Wednesday announced it obtained Part 135 certification from the Civil Aviation Authority (CAA) of New Zealand for future air freight operations in the country. The regulator’s Part 135 covers air operations for helicopters and small airplanes.

Certification of the Merlin’s flagship Merlin Pilot system follows U.S. military airworthiness approvals for fellow automated flight systems providers Xwing and Reliable Robotics, handed out by the U.S. Air Force.

“Achieving an organizational Part 135 certification gives us the opportunity to work with a forward-thinking regulator as well as leverage New Zealand as a sandbox for our current and future products,” said Matt George, founder and CEO of Merlin. “This milestone enables us to continue progressing our technical maturity, ultimately validating the safety and operational effectiveness of the Merlin Pilot for [CAA] Part 23 certification and beyond.”

Merlin’s Part 135 certificate will allow it to perform critical data collection flights on certain regional freight routes following CAA product certification of Merlin Pilot. The company achieved a state of involvement (SOI) 1 milestone for the system in May, putting it on “a viable path to certification and commercial operation,” it said.

According to Merlin, data collected on those freight routes will be essential for “future development decisions that will be implemented globally.” The findings will also support Merlin Pilot certification with both the CAA and FAA, it said.

The company’s Part 135 certification will further allow it to leverage its dedicated test facility in Kerikeri, New Zealand, opened in May, for current and future products once they’re certified.

Merlin said it has made notable progress on its organizational and product certification since its Project Specific Certification Plan (PSCP) was approved by the CAA—in partnership with the FAA—in 2021. At the time, it claimed to be the first company to reach an agreement with a regulator on an approach to certification for autonomous aircraft tech.

Since then, Merlin was contracted by the FAA to perform what it said was the first air cargo network trials flown by a non-human pilot, which it completed successfully in Alaska in July.

The company also has a relationship with the U.S. Air Force. Last week, the two agreed to conduct in-flight demonstrations of Merlin Pilot aboard a KC-135 Stratotanker, which is used by the military for aerial refueling. Those trials will begin next year. The exercise is a follow-up to a 2022 Air Force contract to test the system on a single-pilot Lockheed Martin C-130J Hercules, which is normally commanded by two pilots.

Through innovation arm AFWERX, the Air Force is also collaborating with autonomous flight systems providers Xwing and Reliable Robotics. Both firms were approved to fly in unrestricted airspace in the past 30 days as the military and FAA begin to ramp up their pursuit of autonomy.

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In 1998—25 years ago—Air Journey was founded to help pilots achieve dreams of long-distance travel with their airplanes. The company now leads globally with its escorted flying journeys. The first trip took four GA pilots flying their airplanes to the southern Caribbean islands of San Salvador, Stella Maris, and Andros. Now, Air Journey has grown to a company approaching $10 million in sales and itineraries ranging from 4 to 76 days, and visiting up to 27 countries.

To celebrate the anniversary, Air Journey plans an extraordinary adventure, Islands of the Indian Ocean and Beyond, to transpire from May 24 to July 22 this summer. The trip will bring pilots flying their own aircraft to the islands of the Maldives, Seychelles, Mauritius, and Madagascar, along with excursions to Europe and Africa, including gorilla trekking in Rwanda.

“On our Escorted Journeys, pilots fly their own airplanes in small groups on prearranged itineraries by the AJ Team to destinations across the world,” said owner and founder Thierry Pouille in a release. “Every journey is led by experienced Pilot and Journey Directors and each leg is expertly created to accommodate single-engine turboprop to light-jet aircraft, never exceeding 1,100 nautical miles.”

A Journey for Everyone

In its release, Air Journey highlighted a few of its milestone itineraries over the years. “In 2007, the company launched the first Around the World Journey at Sun ‘n Fun [Aerospace Expo] and took off in 2008 for its Eastbound Around the World [trip]. Milestone destinations to follow included Africa in 2011, Australia in 2017, and the Islands of the Indian Ocean in 2022.” This year, 2023, marks another special journey for Air Journey—the first roundtrip circumnavigation of Australia and New Zealand via Europe in April.

How It Works

The Escorted Journeys come thoroughly planned and executed by the Air Journey pilots and facilitators traveling with you. However, if you want to travel independently, Air Journey also provides its Concierge Service for assistance with planning and is reachable during the trip. In partnership with several pilot and owner associations, Air Journey also organizes Association Journeys where pilots can fly with like-minded companions in similar aircraft models.

To learn more about Air Journey and access the 2023 trip calendar, visit airjourney.com or call +1 561-371-6661.

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The New Zealand Government entered into an agreement with the U.S. Navy for the P-8A aircraft in July 2018.

“As a maritime nation, delivery of the P-8A will ensure New Zealand maintains a patrol and response capability that will protect and support law enforcement in our Exclusive Economic Zone and the Southern Ocean,” Sarah Minson, acting Deputy Secretary of Capability Delivery, New Zealand Ministry of Defense, said in a statement.

The P-8 is a long-range anti-submarine warfare, anti-surface warfare, intelligence, surveillance, and reconnaissance (ISR) aircraft. It has been used for maritime, littoral, and humanitarian missions and operations worldwide. Boing said the global operating P-8 fleet has, to date, amassed more than 450,000 mishap-free flight hours.

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As for the three-remaining aircraft, Boeing said they are all in the advanced stages of production and will be delivered in 2023. They will replace New Zealand’s fleet of six P-3K2 Orions and will be based at the Royal New Zealand Air Force Base Ohakea.

Minson also said the new aircraft would allow New Zealand to assist its neighboring countries in the South Pacific, and they would also use them for long-range search and rescue capabilities.

“The unmatched, multi-mission maritime patrol capabilities of the P-8 will provide New Zealand the ability to extend their reach into the Pacific and beyond,” said Philip June, vice president, and program manager for the P-8 Programs.

Boeing Defense Australia will also provide sustainment services for the new fleet with the support of the P-8 International Program.

“New Zealand joins eight global customers, including nearby Australia, that have selected or already operate the P-8 and benefit greatly from its long-range maritime surveillance and warfare capabilities,” June said.

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If all goes as planned, a passenger-transport trial using an autonomous, all-electric air taxi called Cora may soon begin in Canterbury, New Zealand, as reported in a press release by Wisk this week. That government recently inked a memorandum of understanding with Wisk, an urban mobility company based in Mountain View, California. Wisk was created in 2019 as a joint venture between The Boeing Company and Kitty Hawk Corporation. With the agreement in place, planning for a passenger transport trial in Canterbury is now underway. Once established, the passenger route is expected to be the world’s first and will commence after Cora’s certification by the New Zealand Civil Aviation Authority.

In October 2019, the New Zealand government announced it was establishing an industry-wide airspace integration trial to work with leading domestic and international industry partners to safely test and demonstrate unmanned aircraft. Wisk was announced as the first industry partner to join the program.

Wisk CEO, Gary Gysin, said, “We see this agreement as a sign of confidence in our product and abilities to develop and deliver a safe and reliable air taxi service, starting in New Zealand.” In a news release, Wisk also said, “Urban Air Mobility is an emerging, high-value industry, and New Zealand is an attractive location because of its thriving innovation ecosystem with unique expertise, people and technology.”

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