Framingham, Massachusetts, September 4, 2025 – Re:Build Manufacturing, a leader in high-performance engineering and manufacturing for the aerospace and defense industries, announced today that it has been selected to work with Otto Aviation to design and manufacture the structural control surfaces for Otto’s Phantom 3500 aircraft.
The Phantom 3500’s distinctive laminar flow fuselage and high-aspect-ratio wing demands precision-tooled, tight-tolerance control surfaces to support low-drag flight, enabling Otto to meet its goal of burning 60 percent less fuel than its super-midsize jet competitors and reducing emissions by up to 90 percent when combined with sustainable aviation fuel. To meet these specifications, Re:Build is working closely with the Otto engineering team to produce designs that meet structural requirements while also utilizing tooling and assembly strategies that enable the surfaces to meet the tolerance levels required to minimize aerodynamic drag dramatically.
The Phantom 3500 is an all-composite airframe requiring tight tolerance structural interfaces to the wing and empennage to support the required aerodynamic profile and enable Otto’s laminar flow concept. Re:Build is utilizing its team of engineers and composites manufacturing experts to collaborate with Otto’s internal engineering team to ensure the control surfaces will enable the critical aerodynamic requirements of the Phantom 3500. “Our goal is to engage with customers and products at the forefront of high-impact industries, where we can simultaneously solve for quality, timeliness, and cost, all of which further Re:Build’s mission of onshoring advanced manufacturing,” says Miles Arnone, co-founder and CEO of Re:Build Manufacturing. “Collaborating with Otto on their laminar flow design is an example of the level of engineering expertise and rigor, coupled with stringent manufacturing quality, required to enable the American manufacturing ecosystem.”
The highly optimized aerodynamic design of the control surfaces demonstrates Re:Build’s ability to develop and produce cutting-edge aerospace structural assemblies, seamlessly integrating them into the larger engineering teams and visions of its customers. Re:Build will leverage its aerospace structures design and analysis expertise along with its thermoset composite manufacturing capabilities for this effort. Re:Build is excited to collaborate with Otto on the development of the initial pre-production airframes and then scale production alongside the Otto team as the vehicle transitions from certification to production.
The Phantom 3500 is expected to begin flight testing in 2027, with entry into service targeted for 2030.
About Re:Build Manufacturing
Re:Build Manufacturing is building a better future for its customers, employees, communities, and shareholders by revitalizing America’s manufacturing base and creating meaningful, sustainable jobs in historically deindustrialized regions. With more than 1,100 employees, including over 400 engineers, we solve complex multidisciplinary challenges by combining our advanced manufacturing operations with robust engineering capabilities to help customers grow competitive, resilient businesses close to home.
About Otto Aviation
Otto Aviation is an advanced aerospace company committed to transforming private and regional aviation through innovative aircraft design. Headquartered in Fort Worth, Texas, Otto is developing the Phantom 3500, a new, clean-sheet design aircraft that establishes – and leads – a new category in highly efficient, affordable, and sustainable business jet aviation. Learn more at https://ottoaviation.com/
Cassie Koenen
Senior Marketing Manager
cassie.koenen@rebuildmanufacturing.com