Case Study: DarkAero achieves rapid, cost-effective sourcing of complex CNC and composite aircraft parts with Xometry

DarkAero Soars to New Heights With Machined Parts From Xometry

DarkAero, a startup founded by the Karl brothers building the sleek, long‑range prototype “DarkAero 1,” needed affordable, complex CNC‑machined parts on tight timelines to progress from kit design to a flying prototype. To solve that challenge they turned to Xometry, using Xometry’s CNC machining, CNC milling and aerospace CNC turning services as well as its Supplier Marketplace and Fusion 360 add‑in for rapid quoting and procurement.

Xometry supplied multiple custom machined components (including four custom mount/gearbox housings and a CNC‑turned pivot pin), enabling DarkAero to source parts quickly, reduce lead time and avoid costly in‑house tooling. By using Xometry’s services and Fusion 360 integration, DarkAero saved time and money, accelerated prototype assembly and stayed on track for upcoming flight testing and other development milestones.

DarkAero

Keegan Karl

Cofounder