Re:Build Manufacturing, a leader in high-performance engineering and manufacturing for the aerospace and defence industries, announced today that it has been selected to work with Otto Aviation to design and manufacture the structural control surfaces for Otto's Phantom 3500 aircraft.

The Phantom 3500's distinctive laminar flow fuselage and high-aspect-ratio wing demands precision-tooled, tight-tolerance control surfaces to support low-drag flight, enabling Otto to meet its goal of burning 60 per cent less fuel than its super-midsize jet competitors and reducing emissions by up to 90 per cent when combined with sustainable aviation fuel. To meet these specifications, Re:Build is working closely with the Otto engineering team to produce designs that meet structural requirements while also utilising tooling and assembly strategies that enable the surfaces to meet the tolerance levels required to minimise aerodynamic drag dramatically.

The Phantom 3500 is an all-composite airframe requiring tight tolerance structural interfaces to the wing and empennage to support the required aerodynamic profile and enable Otto's laminar flow concept. Re:Build is utilising its team of engineers and composites manufacturing experts to collaborate with Otto's internal engineering team to ensure the control surfaces will enable the critical aerodynamic requirements of the Phantom 3500. "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, all of which further Re:Build's mission of onshoring advanced manufacturing," says Miles Arnone, co-founder and CEO of Re:Build Manufacturing. "Collaborating with Otto on their laminar flow design is an example of the level of engineering expertise and rigour, coupled with stringent manufacturing quality, required to enable the American manufacturing ecosystem."

The highly optimised aerodynamic design of the control surfaces demonstrates Re:Build's ability to develop and produce cutting-edge aerospace structural assemblies, seamlessly integrating them into the larger engineering teams and visions of its customers. Re:Build will leverage its aerospace structures design and analysis expertise along with its thermoset composite manufacturing capabilities for this effort. Re:Build is excited to collaborate with Otto on the development of the initial pre-production airframes and then scale production alongside the Otto team as the vehicle transitions from certification to production.

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