In October 2013, Costa joined the Red Bull Air Race World Championship as flight operations manager, development and ferry pilot.

[8] and also became the first pilot, together with Ben Murphy, to ever perform a Red Bull Air Race demo at the Farnborough International Airshow, the world's second-largest show of its kind.

[13] In July 2020, Costa became the first airplane pilot to ever fly at low level, in this occasion for the F1 Styrian GP, along the whole Red Bull Ring racetrack for a kind of track preview video never done before.

In October 2020, Costa has performed in two of the break dance competition Red Bull BC One World Finals announcement videos, flying in synchro with dancer Rico Coker.

[18] On 20 June 2022 a scientific article about the Tunnel Pass project was published by Costa and written together with Mikel Lucas Garcia de Albeniz Martinez, Barbara Forster, Peter Adrian Leitl and Andreas Flaschger.

Four professional high divers have performed in this project: Alessandro De Rose, Catalin Preda, Artem Silchenko, Aidan Heslop, coordinated by Orlando Duque.

[23] On 3 November 2022 the book "il Tunnel Perfetto" written in Italian language by Dario Costa and co-writer Biagio D'Angelo was published by Edizioni Minerva.

[24] After almost a year of work with his partner Prada, in early 2023, the world's first specifically made race and aerobatic flight suit, shoes and gloves were unveiled with two dedicated movies.

[26] In September 2023, Dario becomes the first ever to fly a slalom in between moving boats, in this case the two AC40 from Luna Rossa Prada Pirelli and Alinghi Red Bull Racing teams competing at the America's Cup foiling in Vilanova i la Geltrù (Spain) at about 50 km/h.