At Wisk, every team plays a crucial role in bringing our autonomous air taxi to life. But few are as central to the process as the team that runs our "Iron Bird" rig in Fremont, CA. The Iron Bird is a modern integration rig based on hardware-in-the-loop technology. It is a  ground-based replica of our aircraft's core systems, designed to test, debug, and retest every component before it reaches the aircraft. 

The Iron Bird team doesn’t just build and test, they're about building confidence. We sat down with three key team members—Salman, Chad, and Deepak—to learn more about their work, unique challenges, and what it's like to build the future of flight.

The Role of a Modern Test Rig

Salman Khan is the Lead Verification Engineer. He explains how test rigs like the Iron Bird have evolved from simple setups to sophisticated, integrated systems. "The Iron Bird is a modern integration system based on hardware-in-the-loop," he says. This means real aircraft components are connected to a simulated environment, allowing the team to test how the hardware and software behave under a wide range of conditions. This flexibility is a huge advantage, providing flight test engineers with critical information and ensuring the system is ready for flight tests.

But what does it take to create such a complex system? According to Salman, it requires a clear understanding of what you need to test, what equipment you’ll host, what kind of simulation environment you'll create, and the facility needed to house it. "With our very good team, we were able to produce a very competent platform," he says with pride.

A Day in the Life on the Iron Bird

As a Project Engineer, Chad Junio-Pugh's role is to coordinate all the activities on the Iron Bird. The rig is a hub for multiple teams—including aircraft, propulsion, and battery teams—all of whom rely on it for testing. "My role is really understanding their testing request and working to coordinate all of the various testing activities so that we can get the most efficient use out of the Iron Bird," Chad explains.

The ultimate goal of the rig is to find any issues before the components are installed on the actual aircraft. When an issue arises, the team uses a "snag" process to document what happened, identify the responsible team, and implement fixes. This feedback loop not only resolves immediate problems but also improves future designs.

Safety is also a top priority. Chad details the extensive safety measures, from pre-test inspection checklists and high-voltage power shut-off systems to thorough operator training and lockout procedures. "We need to be trained on all the different aspects of operating the rig," he says, emphasizing the importance of understanding both the hardware and software.

The Heartbeat of the Rig

As the Iron Bird's Product Owner, Deepak Kothari focuses on maintaining and ensuring the rig runs efficiently. He calls the Iron Bird a "supercharging station" because it allows the team to find and fix issues early in the development cycle. "Our whole goal is to make sure that all the rigs are in a very compatible manner with what the aircraft will be," Deepak says. "We are the gatekeepers for the aircraft."

He compares building the aircraft to a LEGO set, with each person adding their expertise, piece by piece. This collective effort, he believes, is what will help Wisk succeed. When asked about his personal connection to Wisk's mission, Deepak says it's all about testing. "My core philosophy throughout life is test, test, test," he says with a smile.

The Final Step on the Ground

The work done on the Iron Bird is a critical part of the journey toward bringing safe, everyday flight to life. By building a rigorous testing infrastructure and methodology, the team ensures that every component is thoroughly validated before it ever reaches the aircraft. Their efforts give flight test teams the confidence to focus on the unique challenges of flying, rather than troubleshooting on the ground. In short, the Iron Bird team is helping to reduce risk, increase efficiency, and safeguard the path forward.