EP 85 — Hermeus' Zach Shore on Building Mach 5 Aircraft & the Path to Reusable Hypersonics
by Chris Petersen on Feb 13, 2026

Quarterhorse, their 30,000-pound Mach 2+ aircraft powered by the F100-229, flies from White Sands this year. It's not a test article; it's the first platform with actual utility. Think unmanned F-16 capability stack: electronic warfare, rails for weapons, red air, high-speed target. Darkhorse will hit low Mach 5 before decade's end. Zach walks through why they're building metal airframes with removable panels and modular inlets rather than exotic composites, how they're using proven components like the F-16 landing gear and MiG fuselage design to avoid reinventing solved problems, and why demonstrating incremental capability beats PowerPoint pitches when you're trying to crack into integrated heavy systems programs.
Topics discussed:
- Demonstrating turbine-based combined cycle engine architecture in wind tunnel for $20M versus NASA/DARPA's nine-figure development
- Routing airflow around cocooned F100-229 turbine into ramjet at Mach 3 to achieve reusable Mach 5 flight capability
- Building 10,000-pound unmanned aircraft from design to flight in 15 months to validate high-speed outer mold line
- Deploying Quarterhorse 30,000-pound Mach 2+ platform with F-16 capability stack including electronic warfare and weapons rails
- Designing metal airframes with removable panels and modular inlets rather than exotic composites for production scalability
- Using proven components like F-16 landing gear and MiG fuselage design to avoid reinventing solved engineering problems
- Navigating defense R&D contracting where labs compete with private innovators and prime contractors receive cost-plus incentives
- Building hardware-rich iterative development approach with smaller engines before scaling to full F100-229 and ramjet integration
Listen to more episodes:
You May Also Like
These Related Stories

EP 63 — Method MFG’s Rhys Andersen on Bootstrapping a Machine Shop into Aerospace Manufacturing

EP 84 — Ashish Parikh on Building Mesh Radios That Frequency-Hop Faster Than Jammers Can Track


No Comments Yet
Let us know what you think