The U.S. Air Force has completed flight testing of an adaptive seat cushion for the B-52H Stratofortress aimed at reducing aircrew fatigue during long-duration missions, according to the U.S. Air Force.
The evaluation was carried out in early November by the 49th Test and Evaluation Squadron (TES) in coordination with Air Force Global Strike Command’s Commercial Capabilities and Integration and Transition Division. During the sortie, aircrew installed and tested three Kalogon Smart Cushions aboard a B-52H to assess airworthiness, comfort and performance impacts during extended flight.
The testing follows congressional concern over the effects of inadequate seating on aircrew endurance. House Armed Services Committee legislation identified crew fatigue linked to legacy seating as a factor affecting mission effectiveness, prompting Global Strike Command to pursue new solutions through an AFWERX Small Business Innovation and Research contract.
The system under evaluation, known as the Orbiter Ace, is designed to automatically redistribute pressure while seated, improving circulation and reducing physical strain without requiring manual adjustment by the crew. Kalogon says the technology is intended for missions lasting 24 to 36 hours, a profile common to B-52 operations.
Kalogon’s core technology functions because it allows blood flow to return to previously pinched muscle cells, said Jake Milanowski, Kalogon systems engineer. Increased blood flow while seated prevents muscle deterioration and helps prevent cell death. Better spinal support and positioning can prevent long-term back pain, which can impair daily activities and in-flight movement.
During the five-hour test flight, crews completed pre- and post-mission surveys assessing comfort, circulation and fatigue. That feedback will be compiled into a report to determine whether design changes are required before further testing.
Master Sgt. Christopher Lawn, Air Force Global Strike Command aircrew flight equipment requirements manager, said improved seating could have broad benefits. By providing a seat cushion that enhances aircrew comfort during long-duration missions, I believe crewmembers will experience benefits both in performing their primary mission and in their overall health, he said.
Based on initial results, the Air Force plans to manufacture nine additional cushions in early 2026 and conduct a longer sortie with a full B-52 crew. If the system meets airworthiness and performance requirements, it could transition into service across the B-52 fleet. U.S. Air Force Global Strike Command is also reviewing the technology for potential use on other platforms, including the E-4B, B-1B Lancer and missile launch control centers, as part of wider efforts to improve endurance and crew health on long-duration missions.