DarkAero, a pioneering aerospace company founded by brothers Keegan, River, and Ryley Karl, is on a mission to revolutionize personal aviation by creating high-performance aircraft kits that enthusiasts and builders can assemble themselves. Based in Madison, Wisconsin, DarkAero combines engineering expertise with sophisticated manufacturing techniques to develop aircraft designed for speed, efficiency, and long-range travel. Central to their manufacturing process is the Tormach 1500MX CNC mill, which has become an indispensable tool for both prototyping and production. “We’re now transitioning from the prototyping stage into flight testing and production activities. Throughout the whole process, we have been using Tormach equipment, including the 1100 PCNC and now our newest model, the 1500MX,” says Keegan Karl, co-founder and vice president of DarkAero.
Redefining the Future of Personal Aviation
DarkAero’s innovative approach focuses on creating aircraft that combine lightweight composite materials with precision-engineered metal components. With Tormach’s 1500MX CNC mill, they can produce complex parts in-house, enabling them to quickly iterate on designs and bring their vision to life. The new Tormach 1500MX, with its 10,000 RPM spindle and rapid movements, has drastically improved their workflow, enhancing their ability to create accurate, production-ready parts.
The Role of Tormach 1500MX in Production
The Tormach 1500MX has been a game-changer for DarkAero, allowing them to streamline their manufacturing process and improve precision. “We were really excited to have the very first 1500MX unit in our shop to test out and see what it’s capable of,” Karl shares. “We learned quickly that this machine is extremely capable. The spindle can go up to 10,000 RPM. It also has rapid movements of 1,200 inches per minute for X and Y, and 600 inches per minute for Z, which means it has a greater rate of material removal than the previous model.” These advanced features, including through-spindle coolant, mist collector, and washdown capability, have reduced manual setup and cleanup time, enabling DarkAero to focus more on innovation and less on maintenance.
Read more industry coverage about darkaero and the 1500MX
- Cutting Tool Engineering Magazine
- Manufacturing & Engineering Magazine
- Manufacturing.net
- Today's Machining World
- Industrial Equipment News
A Game-Changing Partnership
The collaboration with Tormach has been instrumental in DarkAero’s ability to bring their aircraft designs to life. “On the 1500MX, the coolant comes out of the spindle head and can go through the tools, which helps in reducing tool wear, improving cutting efficiency, and maintaining tighter tolerances on the machined parts,” says Karl. “It also has a washdown feature that takes all the chips generated during the machining process and funnels them into a collection unit at the back. This is a huge upgrade from what we had before.” The Tormach 1500MX’s automated features, such as the automatic tool changer and built-in camera for monitoring, have also been crucial in making their production process more efficient and less error-prone.
For DarkAero, having the capability to prototype and manufacture parts in-house is a significant advantage, allowing them to refine designs and adapt quickly. “There are benefits to outsourcing, but if you have the capability to do it all under one roof, things can happen much more quickly,” Karl explains. “We can make changes on the fly, update the CAM, and run with it. This tight feedback loop has been invaluable for us.” As they continue to innovate and push the boundaries of personal aviation, the Tormach 1500MX will remain a cornerstone of their manufacturing success.
