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Description

Engineer Fernando Mier-Hicks inspects a test stand used to investigate the performance of next-generation Mars helicopter rotor blades at high speeds inside the 25-Foot Space Simulator at NASA’s Jet Propulsion Laboratory in Southern California in November 2025. Data from the tests indicate that the rotors could surpass the sound barrier without breaking apart.

The test campaign was funded by the agency’s Mars Exploration Program in pursuit of maximizing the capability of future aircraft flying at the Red Planet. A division of Caltech in Pasadena, JPL manages the Mars Exploration Program for NASA’s Science Mission Directorate in Washington.

Description

Engineer Jaakko Karras inspects a next-generation Mars helicopter rotor blade prior to supersonic speed testing in the 25-Foot Space Simulator at NASA’s Jet Propulsion Laboratory in Southern California in November 2025. The three-bladed rotor hanging horizontally in the foreground is the next-gen rotor being tested. The vertically aligned two-bladed rotor provided a “headwind,” enabling the tips of the three-bladed rotor to go beyond Mach 1. Data from the tests indicate that the next-gen rotor could surpass the sound barrier without breaking apart.

The agency’s Mars Exploration Program funded the test campaign in pursuit of maximizing the capability of future aircraft flying at the Red Planet. A division of Caltech in Pasadena, JPL manages the Mars Exploration Program for NASA’s Science Mission Directorate in Washington.

The rotor blades that will carry NASA’s next-generation helicopters to new Martian heights broke the sound barrier during March tests at NASA’s Jet Propulsion Laboratory in Southern California. Data from the tests, which took place in a special chamber that can simulate environmental conditions on the Red Planet, indicate that the fastest traveling part of the rotor blade, the tips, can be accelerated beyond Mach 1 without breaking apart. Data gathered from 137 test runs will enable engineers to design aircraft capable of carrying heavier payloads, including science instruments.

“NASA had a great run with the Ingenuity Mars Helicopter, but we are asking these next-generation aircraft to do even more at the Red Planet,” said Al Chen, Mars Exploration Program manager at JPL. “That’s not an easy ask. While everything about Mars is hard, flying there is just about the hardest thing you can do. That’s because its atmosphere is so incredibly thin that it is hard to generate lift, and yet Mars has significant gravity.”

Ingenuity, which performed the first powered, controlled flight on another world just over five years ago on April 19, 2021, was a trailblazing technology demonstration that did not carry science instruments. The agency’s recently announced SkyFall project and other potential future Mars aircraft will be capable of carrying payloads — including science instruments and sensors — to collect data in support of future human and robotic missions, leveraging the advantages that come with low-altitude aerial exploration.

Need for speed

In the fast-moving world of rotors, more thrust comes from a quicker spin or a larger diameter. Although this axiom holds true on Earth, engineers designing aircraft for the Red Planet must be much more aggressive. Because the Mars atmosphere is only 1% as dense as Earth’s, maximizing thrust requires pushing blade tips toward the speed of sound to achieve significant lift. While small-diameter rotors on Earth can also rotate at thousands of revolutions per minute, they have more air molecules to push and don’t need to approach the sonic edge.

The Ingenuity flight team never allowed the rotational speed of their composite-skinned foam rotors to exceed 2,700 rpm during the helicopter’s 72 flights at Mars for two reasons: to avoid the unpredictable physics of the sound barrier and to make sure that an unexpected gust of wind (from a dust devil, for instance) wouldn’t send the rotor tips over the sonic edge.

“If Chuck Yeager were here, he’d tell you things can get squirrely around Mach 1,” said JPL’s Jaakko Karras, the rotor test lead. “With that in mind, we planned Ingenuity’s flights to keep the rotor blade tips at Mach 0.7 with no wind so that if we encountered a Martian headwind while in flight, the rotor tips wouldn’t go supersonic. But we want more performance from our next-gen Mars aircraft. We needed to know that our rotors could go faster safely.”

While Mach 1 on Earth at sea level is approximately 760 mph (1,223 kph), the speed of sound on Mars is significantly slower — roughly 540 mph (869 kph) — due to the planet’s thin, cold, carbon-dioxide-rich atmosphere.

Blade-proof chamber

To begin evaluating the rotors, which were developed and manufactured by AeroVironment in Simi Valley, California, Karras and his team mounted a three-bladed rotor that could be used in future Mars helicopter designs inside the historic 25-Foot Space Simulator at JPL. They evacuated the air and replaced it with just enough carbon dioxide to match the Martian atmosphere, then blasted the rotor with wind as it spun at increasing speeds.

The test engineers had taken the precaution of lining part of the chamber with sheet metal in case the blades broke apart during the supersonic experiment. From a control room a few yards away from the chamber, the team watched displays showing data and a view inside the chamber as the rpm climbed as high as 3,750. At that rate, the tips were traveling at Mach 0.98. Then the engineers activated a fan inside the chamber that pelted the rotors with headwinds. After each run, they increased in wind velocity for the next run.

The team pushed rotor tip speeds to Mach 1.08, boosting the Mars vehicle’s lift capability by 30%. This breakthrough allows future missions to support heavier scientific payloads, including advanced sensors and larger batteries for extended flight.

Next the team tried their luck with the two-bladed SkyFall rotor. Because it is slightly longer than the three-bladed version, only 3,570 rpm was needed to achieve the same near-supersonic speed at the rotor tips prior to introducing the headwinds.

“The successful testing of these rotors was a major step toward proving the feasibility of flight in more demanding environments, which is key for next-gen vehicles,” said Shannah Withrow-Maser, an aerodynamicist from NASA’s Ames Research Center in Silicon Valley and member of the test team. “We thought we’d be lucky to hit Mach 1.05, and we reached Mach 1.08 on our last runs. We’re still digging into the data, and there may be even more thrust on the table. These next-gen helicopters are going to be amazing.”

The SkyFall mission design team has incorporated the test team’s findings into the performance specifications. Inspired by Ingenuity, the only rotorcraft to fly on another planet to date, SkyFall is designed to carry three next-gen Mars helicopters to the Red Planet in December 2028.

More about NASA’s Mars Exploration Program

The faster-than-sound spin test campaign was funded by the agency’s Mars Exploration Program in pursuit of maximizing the capability of future aircraft flying at the Red Planet. A division of Caltech in Pasadena, JPL manages the Mars Exploration Program for NASA’s Science Mission Directorate in Washington.  

For more information about NASA’s Mars Exploration Program, visit:

https://mars.nasa.gov

Media Contacts

DC Agle
Jet Propulsion Laboratory, Pasadena, Calif.
818-393-9011
agle@jpl.nasa.gov

Karen Fox / Alana Johnson
NASA Headquarters, Washington
240-285-5155 / 202-672-4780
karen.c.fox@nasa.gov / alana.r.johnson@nasa.gov

2026-029

A full-scale mock-up of a crew cabin for a future industry lunar lander for NASA’s Artemis program now is operational for training and testing. The agency and its industry partners will use Blue Origin’s Blue Moon Mark 2 crew cabin for mission simulations as the agency prepares to dock with landers in Earth orbit in 2027 and send astronauts to the Moon by 2028.

NASA is working with two American companies to develop the human landing systems that will safely transport astronauts from lunar orbit to the Moon’s surface and back for Artemis. Blue Origin’s lander, launching uncrewed on top of the company’s New Glenn rocket, will meet astronauts aboard NASA’s Orion spacecraft in lunar orbit. Two astronauts will board the Blue Moon crew lander, which will ferry them to the surface and back to other crew members aboard Orion in lunar orbit following the conclusion of their surface stay.

The Blue Moon crew lander that will fly to the Moon will stand about 52 feet tall. Its crew cabin, located at the base of the lander, will be the living and working space where two astronauts will eat, sleep, conduct science, and observe the lunar environment during their stay.

The prototype at NASA’s Johnson Space Center in Houston is a full-size model, featuring the exterior ladder astronauts will use during their time on the Moon. As NASA and industry teams prepare for future crewed missions to the lunar surface, this model will evolve to support more advanced mission and training needs. Over time, it will become an integrated simulator with interactive systems that help astronauts practice for their flight with ground flight control teams.

NASA and Blue Origin can access the exterior and interior of the crew cabin trainer to conduct a series of human-in-the-loop tests, or tests with human interaction, including mission scenarios, mission control communications, spacesuit checkouts, and preparations for simulated moonwalks. The training cabin will also be used to provide design feedback to the Blue Origin team as the lander continues to be developed and mission planning evolves.

Following the successful Artemis II test flight that took four astronauts around the Moon, NASA will launch the Artemis III mission next year to test critical systems in Earth orbit, including rendezvous and docking with one or both commercial landers from Blue Origin and SpaceX. The agency and its partners will conduct integrated checkouts of life support, communications, propulsion, and potentially new spacesuits. These operations will pave the way for Artemis IV and V in 2028, which will return NASA astronauts to the Moon using these commercial provide landers.

Under Artemis, NASA will send astronauts on increasingly difficult missions to explore more of the Moon for scientific discovery and economic benefits, building the foundation for the first crewed missions to Mars.

Learn more about the Artemis program:

https://www.nasa.gov/artemis

A thin sliver of Earth’s edge is brightly illuminated against the vast darkness of space in this April 3, 2026, image taken during the Artemis II mission. Artemis II was the first crewed flight in a series of missions to test NASA’s human deep space capabilities, paving the way for future lunar surface missions.

See more imagery from the Artemis II mission.

Image credit: NASA

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