Scaled Composites’ Model 437 Returns to Flight for Beacon Autonomy Tests

Scaled Composites’ Model 437 Vanguard returned to the skies on 20 September 2025, beginning a new phase of envelope expansion flights after undergoing major upgrades since its first flight in 2024. The test campaign is a crucial step before the aircraft supports Northrop Grumman’s Beacon autonomy trials, which will evaluate advanced autonomous flight technologies.

Major Upgrades and Preparations

In preparation for this new role, engineers completed significant work on the aircraft, including:

• Updates to the hydraulic system

• Integration of Beacon subsystems within the airframe

• Installation of pilot interfaces in the cockpit for safety pilot operations

• Joint hangar tests by Scaled Composites and Northrop Grumman to verify the Beacon autonomy ecosystem before flight

Project engineer Yuto Shinagawa explained that the transformation required turning an airplane that had only flown once into a versatile autonomous testbed. A key challenge was ensuring flight safety protections when engaging the autonomous system and integrating those protections directly into the flight controls.

Model 437 Capabilities

The Model 437 Vanguard is a medium-class jet testbed designed with autonomy and payload flexibility in mind. Key specifications include:

• Length and wingspan: approximately 41 feet each

• Engine: single Pratt & Whitney 535, producing around 3,400 pounds of thrust

• Gross takeoff weight: about 10,000 pounds

• Payload capacity: up to 2,000 pounds, with an internal bay measuring roughly 145 × 36 × 16 inches

• Range and endurance: up to 3,000 nautical miles and six hours

These features make the aircraft particularly suited for autonomy testing, offering endurance, payload flexibility, and the ability to operate in both manned and unmanned configurations.

The Beacon Autonomy Ecosystem

Beacon is Northrop Grumman’s open-architecture testbed initiative designed to accelerate the development of autonomy software. The system provides:

• An optionally autonomous aircraft with safety pilots on board

• Open interfaces and sensors that allow different autonomy developers to integrate and test their systems

• A platform for collaboration with leading autonomy partners, including Applied Intuition, Autonodyne, Merlin, Red 6, Shield AI, and SoarTech

By bridging the gap between lab testing and real-world flight trials, Beacon aims to speed up the deployment of autonomous systems into operational environments while maintaining strict safety standards.

Expanding the Flight Envelope

The ongoing test flights focus on gradually expanding the operating envelope of the Model 437. Engineers are pushing the aircraft to higher airspeeds, altitudes, and maneuvering limits to validate safety margins and ensure the integrity of the control systems, particularly under autonomous operation. These tests are critical to proving that the aircraft can safely handle the stresses and demands of autonomy before the Beacon trials begin.

Significance of the Programme

The resumption of flight testing demonstrates Scaled Composites’ agility in rapidly modifying aircraft for advanced test objectives. Combined with Northrop Grumman’s expertise in autonomy, the programme has accelerated progress in developing and refining autonomy software.

The Model 437 Vanguard is now positioned as a central platform for future autonomous aviation advancements, enabling partners to test next-generation autonomy solutions in realistic flight conditions. Its role in the Beacon initiative underscores its importance in shaping the future of autonomous air operations.