From 1992 to 1999, this was one of the most forward-thinking projects in the single-seat stealth technology demonstrator Boeing Bird of Prey. Done at the secretive Area 51, this aircraft was built to test advanced stealth techniques and some new ways to design and build aircraft. As its name, that came from the Klingon spacecraft in Star Trek, evokes, it was rather futuristic and otherworldly.
The Bird of Prey flew for the first time in the fall of 1996, and in 38 flights, the new approaches for an aircraft to be less observable to the eye and radar were demonstrated. The aircraft also introduced innovations that included large single-piece composite structures, “virtual reality” computerized design and assembly, and disposable tooling. These technologies and methods are today the standard industry technology, and directly influenced subsequent Boeing programs, including the X-32 Joint Strike Fighter and the X-45A Unmanned Combat Air Vehicle.
The most famous characteristics of the Bird of Prey were the “gapless” control surfaces. These control surfaces blended into the wings without visible seams to reduce the radar visibility of this aircraft. Also, the engine intake was fully covered at the front, which added to its ability to remain stealthy. While quite advanced in its design, the Bird of Prey did sport some “off the shelf” technology to reduce production costs and speed up the production process. The control system was purely manual, without any computer assistance, and the landing gear was adapted from the Beech King Air and Queen Air.
It truly was a case of cost-effective innovation. Unlike most stealth programs, which are notorious for their cost, from concept to flight, the Bird of Prey costs less than a single F-35 does today. “The Bird of Prey wasn’t aiming for operational service, but elements of its design and production process are still working their way into Uncle Sam’s hangars to this very day,” noted one expert.
The Bird of Prey was developed by McDonnell Douglas’ Phantom Works division, which is now part of Boeing Integrated Defense Systems. He had a project lead named Alan Wiechman, who used rapid prototyping and single-piece composite structures to minimize body panel seams on this stealth aircraft. To this day, that is one of the more difficult tricks of building stealth aircraft, and some say it’s something that Russian stealth fighter programs have continued to struggle with.
It was powered by a single Pratt & Whitney JT15D-5C turbofan engine that cranked out 3,190 pounds of thrust. It had a top speed of 300 mph and a maximum altitude of 20,000 feet. But while that may seem like a relatively modest performance for an advanced spy plane, the Bird of Prey represented major strides in stealth technology.
The Bird of Prey was declassified and shown to the public on 18 October 2002. It was then donated to the National Museum of the United States Air Force at Wright-Patterson Air Force Base where it remains on display.
The bottom line was that the Boeing Bird of Prey represented the forerunner of today, squeezed at the forefront of stealth and aircraft design. This legacy continues to live in contemporary aviation, proving that being innovative does not have to be mutually exclusive to cost-effectiveness.