Investigating Aviation’s Climate Footprint: The DLR and TUI fly Collaboration

In a significant step towards understanding and mitigating the environmental impact of air travel, the German Aerospace Center (DLR) has initiated a pioneering flight campaign in partnership with TUI fly. For the first time in several years, a dedicated research aircraft is trailing scheduled passenger flights to capture real-time data on emissions. This initiative is part of the broader European research project A4CLIMATE, which aims to shed light on the complex relationship between modern engine technology and the formation of condensation trails, commonly known as contrails.

While the aviation industry has long focused on reducing carbon dioxide (CO₂) emissions, scientific consensus increasingly points to non-CO₂ effects as a major contributor to global warming. Specifically, contrails and the resulting cirrus clouds are believed to trap heat in the Earth’s atmosphere. We observe that this collaboration represents a critical shift from theoretical modeling to real-world validation, as researchers seek to determine how modern “lean-burn” engines influence the atmosphere compared to older technologies.

The campaign involves high-precision coordination between scientific pilots and commercial flight crews. By analyzing the exhaust plumes of aircraft in regular service, the project partners aim to develop robust strategies for climate-optimized flight planning. This effort highlights a growing industry trend where operational expertise and atmospheric science converge to address the urgent challenges of Climate change.

The Mission Profile: Chasing Data at 30,000 Feet

The core of this campaign features a DLR Dassault Falcon 20E research aircraft following a TUI fly Boeing 737 MAX 8. The operation requires the research plane to maintain a distance of approximately 10 kilometers (five nautical miles) behind the passenger jet. This specific distance allows the exhaust plume to evolve sufficiently for meaningful measurement while remaining fresh enough to analyze the immediate chemical and physical properties of the emissions.

The flights are currently being conducted on regular routes between Germany and Egypt. These corridors were selected due to their high probability of contrail formation, providing researchers with ample opportunities to gather relevant data. The focus of the study is the Boeing 737 MAX 8, which is equipped with modern CFM International LEAP-1B engines. These engines are characterized by their “lean-burn” combustion technology, which is designed to be more fuel-efficient and emit significantly less soot than previous engine generations.

Instruments onboard the Falcon 20E are tasked with measuring the evolution of soot and volatile particles within the exhaust plume for periods of up to 30 minutes. The primary scientific question driving this specific phase of the research is whether the reduction in soot emissions from these modern engines translates directly to a reduction in persistent contrails. While it is known that soot particles act as nuclei for ice crystals, the exact correlation between reduced soot mass and the number of ice crystals formed remains a complex variable that requires empirical verification.

“We want to understand how much global warming can be reduced when aircraft are more modern and smarter. It is still unclear whether less soot automatically means fewer contrails.”, Christiane Voigt, Project Manager at DLR Institute of Atmospheric Physics.

The Science of Contrails and Climate Impact

To understand the significance of this study, we must look at the mechanics of contrail formation. Contrails are created when hot, humid exhaust gases from aircraft engines mix with the cold air of the upper atmosphere. If the air is sufficiently cold and humid (ice-supersaturated), the water vapor condenses and freezes around particles, primarily soot, emitted by the engines. These ice crystals can persist and spread, forming cirrus clouds that prevent heat from escaping the Earth, a phenomenon known as radiative forcing.

Current scientific estimates suggest that these non-CO₂ effects could be responsible for a substantial portion of aviation’s total climate impact. Some studies indicate that contrails and contrail-induced cirrus clouds might account for up to two-thirds of the sector’s contribution to global warming, or approximately 1% to 2% of total global warming. Unlike CO₂, which remains in the atmosphere for centuries, contrails have a lifespan measured in hours. This presents a unique opportunity: if contrail formation can be prevented, the climate benefit is immediate.

However, the interaction between engine technology and atmospheric physics is not straightforward. While modern engines emit fewer soot particles, the particles that are emitted may still be sufficient to trigger contrail formation under certain conditions. Furthermore, the size and optical properties of the ice crystals formed by lean-burn engines may differ from those formed by older engines, potentially altering their warming effect. The data collected by the Falcon 20E is essential for refining climate models and verifying the accuracy of prediction tools used for flight planning.

The A4CLIMATE Project: A European Initiative

This flight campaign is a central component of the A4CLIMATE project, a major research initiative funded by the European Union. The project brings together a consortium of 17 partners from nine countries, including leading research institutions like the Max Planck Society, ETH Zurich, and Imperial College London, as well as industry heavyweights such as Airbus, Rolls-Royce, and Lufthansa Systems. The goal is to develop practical, science-based solutions to minimize the climate impact of aviation beyond simple fuel efficiency.

The A4CLIMATE strategy explores three primary avenues for mitigation. First, as demonstrated by the current TUI fly campaign, is the assessment of advanced engine technologies and their combustion characteristics. Second, the project is investigating the potential of SAF, which naturally contain fewer aromatics and therefore produce less soot, potentially reducing contrail formation further. Third, the project focuses on climate-optimized routing, or “contrail avoidance.”

Climate-optimized routing involves adjusting flight paths, often by small changes in altitude, to avoid regions of the atmosphere that are supersaturated with ice. If aircraft can fly around or above these “cold and humid” pockets, contrails can be avoided entirely. TUI fly has already been active in this area; since early 2025, the Airlines has routed several hundred flights specifically to avoid long-lasting contrails, providing operational data to researchers. The current measurement campaign serves to validate the predictions that guide these routing decisions.

“As a partner to science, we are providing our flights and our operational expertise. We want to help ensure that research results are quickly incorporated into everyday aviation practice, in order to reduce the climate impact of our flights.”, Christoph Todt, Head of Environmental Sustainability at TUI Airline.

Conclusion and Future Implications

The collaboration between DLR and TUI fly under the A4CLIMATE project marks a pivotal moment in aviation Sustainability research. By directly measuring the emissions of modern aircraft in real-world conditions, the industry is moving closer to understanding the full scope of its environmental footprint. The data gathered from these flights will be instrumental in calibrating the next generation of climate models and validating the effectiveness of new engine technologies.

Looking ahead, the implications of this research extend into regulatory and operational domains. As the European Union moves toward monitoring and reporting non-CO₂ effects, accurate data becomes a prerequisite for compliance. Furthermore, if the hypothesis regarding flight path optimization is validated, we may see a fundamental shift in air traffic management, where climate impact is weighed alongside safety and efficiency in flight planning. This offers a potential “quick win” for the climate, allowing the aviation sector to reduce its warming impact significantly even before zero-emission propulsion technologies become widely available.

FAQ

What is the main goal of the DLR and TUI fly collaboration?
The primary goal is to investigate the climate impact of contrails generated by modern “lean-burn” aircraft engines and to validate flight path optimization strategies that could reduce aviation’s global warming footprint.

How is the data being collected?
A DLR Falcon 20E research aircraft follows TUI fly passenger flights (Boeing 737 MAX 8) at a distance of approximately 10 kilometers to measure the composition and evolution of the exhaust plume in real-time.

Why are contrails considered a climate problem?
Contrails can form cirrus clouds that trap heat in the Earth’s atmosphere. Scientific estimates suggest they may contribute as much or more to global warming than the CO₂ emissions from aviation.

What is the A4CLIMATE project?
A4CLIMATE is an EU-funded research initiative involving 17 partners from 9 countries. It aims to develop solutions to minimize aviation’s climate impact through advanced engines, sustainable fuels, and climate-optimized flight routing.

Sources: TUI Group

Aerofugia Unveils Production-Ready AE200 eVTOL at Aero Asia 2025

The landscape of urban air mobility took a significant step forward in late November 2025 at the Aero Asia Show in Zhuhai, China. Aerofugia, a subsidiary of the automotive giant Geely Technology Group, presented its flagship AE200 eVTOL (electric Vertical Take-Off and Landing) aircraft. This presentation highlighted the AE200-100, a production-ready configuration that recently rolled off the assembly line, signaling a shift from experimental prototyping to imminent commercialization within the burgeoning low-altitude economy.

The event, held at the Zhuhai International Airshow Center, served as a critical platform for the general aviation sector in Asia. While numerous companies showcased concepts for sustainable aviation, Aerofugia’s presence was notable for the maturity of its platform. By leveraging the industrial capabilities of its parent company, Geely, the Chengdu-based startup demonstrated a model that integrates automotive-grade manufacturing processes with aerospace engineering. This convergence is increasingly viewed as a necessary step to achieve the scale required for mass adoption of flying taxis.

We observe that the timing of this unveiling aligns with broader strategic goals in the region. The Chinese government has designated the low-altitude economy, generally defined as flight activities below 3,000 meters, as a strategic emerging industry. With the AE200, Aerofugia positions itself not merely as a participant but as a “chain-master” enterprise, aiming to lead the industrial push in the Chengdu region and beyond. The aircraft is currently in the final phases of compliance flight testing, with a clear roadmap toward full certification.

Engineering the AE200: Performance and Specifications

The AE200 is distinguished by its tilt-rotor configuration, a design choice that separates it from simpler multi-rotor competitors. The aircraft features eight rotors in total; four tilt to facilitate high-speed forward flight, while four remain fixed to provide lift. This architecture allows the AE200 to achieve superior range and speed, making it suitable for inter-city travel as well as intra-city commuting. According to specifications released during the show, the aircraft boasts a range of approximately 200 kilometers (124 miles) and a cruise speed of 248 km/h (154 mph), with a maximum speed reaching 320 km/h (199 mph).

In terms of physical dimensions, the aircraft commands a significant footprint with a wingspan of 14.5 meters, a length of 9 meters, and a height of 4.6 meters. Despite its size, the all-electric propulsion system ensures a quieter operation compared to traditional helicopters, a prerequisite for operating in dense urban environments. The standard cabin layout is configured for one pilot and four passengers (1+4), a setup chosen to maximize passenger comfort and psychological safety during the early adoption phase of eVTOL travel.

However, the platform retains versatility. We note that the cabin is designed as a “6-seater” platform, capable of accommodating a high-density layout of one pilot plus five passengers if required. Alternatively, the interior can be rapidly converted for cargo transport, highlighting the modular nature of the design. This flexibility is essential for operators looking to maximize utilization rates across different service types, from air taxi operations to emergency logistics.

We have adapted proven automotive-grade systems like smart interfaces and ergonomic layouts for use in our eVTOL aircraft… The goal is to make the AE200 a safe, affordable, and comfortable flying vehicle.

The “Smart Flexible Cabin” and Automotive Heritage

A key differentiator for Aerofugia is its direct access to Geely’s automotive supply chain and design philosophy. At the Aero Asia Show, the company introduced what it calls the “Smart Flexible Cabin.” This interior concept rivals luxury automobiles, incorporating features such as ambient lighting, a fragrance system, and a smart interface co-developed with established automotive suppliers. These elements are designed to normalize the flying experience for passengers who may be accustomed to high-end ground vehicles.

The “Flexible Three-Row” design further illustrates this cross-industry innovation. The third row of seats features electronic folding capabilities, allowing the space to be converted for luggage or additional legroom instantly. Safety features also borrow from automotive standards, with the inclusion of aviation-grade energy-absorbing seats and four-point safety belts. By utilizing existing automotive components for non-critical systems, Aerofugia reportedly reduces development costs and streamlines supply chain management.

This strategy addresses one of the most significant hurdles in the eVTOL industry: manufacturing scalability. Unlike traditional aviation startups that must build supply chains from scratch, Aerofugia utilizes Geely’s established networks for components like electric motors and interior materials. This advantage is critical as the company prepares to fulfill its growing order book.

Commercial Momentum and Regulatory Path

The commercial viability of the AE200 is supported by a substantial backlog of orders. Reports indicate that Aerofugia has secured over 1,000 pre-orders for the aircraft. Key clients include major regional players such as Sichuan Airlines, Hualong Airlines, and Sino Jet. The company has stated that its first year of production capacity is already fully booked, reflecting strong market confidence in the platform’s eventual deployment.

On the regulatory front, Aerofugia has made measurable progress with the Civil Aviation Administration of China (CAAC). In May 2025, the company received the CCAR-135 operation certificate from the CAAC Southwest Regional Administration. This certification is a significant milestone, as it authorizes initial commercial operations, such as aerial sightseeing and irregular passenger transport, even before full mass production begins. It allows the company to build operational experience and validate its business models in real-world scenarios.

Looking ahead, the primary focus remains on achieving Type Certification (TC). The AE200 is currently undergoing the final phase of compliance flight testing. The company anticipates receiving its Type Certificate in 2026. This approval is the final regulatory gate required for mass commercial deployment and will likely trigger the delivery of the pre-ordered units to launch customers.

Conclusion

The presentation of the AE200 at the Aero Asia Show 2025 underscores the rapid maturation of the electric aviation sector in China. Aerofugia’s approach, characterized by a blend of aerospace engineering and automotive manufacturing discipline, offers a pragmatic path toward the commercialization of urban air mobility. With a secured order book and a clear regulatory timeline targeting 2026 for Type Certification, the company appears well-positioned to transition from development to delivery.

As the low-altitude economy continues to garner government support and investment, the success of the AE200 will likely serve as a bellwether for the broader industry. The ability to deliver a certified, safe, and comfortable aircraft that leverages the cost efficiencies of the automotive supply chain could set a new standard for eVTOL manufacturers globally. We will continue to monitor the progress of the AE200 as it completes its final compliance tests in the coming year.

FAQ

What is the range and speed of the Aerofugia AE200?
The AE200 has a range of approximately 200 km (124 miles) and a cruise speed of 248 km/h (154 mph). Its maximum speed is 320 km/h (199 mph).

When will the AE200 be available for commercial flights?
Aerofugia expects to receive Type Certification (TC) in 2026, which will allow for mass commercial deployment. However, the company already holds a CCAR-135 operation certificate, allowing for initial operations like aerial sightseeing.

How many passengers can the AE200 carry?
The standard configuration carries one pilot and four passengers (1+4). The cabin is designed as a 6-seater platform and can be configured for high-density transport (1+5) or cargo.

Who backs Aerofugia?
Aerofugia is a subsidiary of the Geely Technology Group, a major Chinese automotive conglomerate. This backing provides access to automotive-grade supply chains and mass manufacturing capabilities.

Sources

• Aerofugia

Strategic Partnership to Launch Electric Air Mobility in Saudi Arabia

We are witnessing a significant shift in the global aviation landscape as Archer Aviation Inc. announces a strategic partnership with The Helicopter Company (THC) and Red Sea Global (RSG). This collaboration marks a pivotal step toward introducing electric vertical takeoff and landing (eVTOL) aircraft to the Kingdom of Saudi Arabia. The initiative is spearheaded by THC, a subsidiary of the Public Investment Fund (PIF), which has selected Archer as a partner to develop and implement these advanced air mobility solutions. The primary objective is to launch a “sandbox” testing program, a controlled environment designed to validate the technology before full-scale commercial operations commence.

The context for this development is Saudi Arabia’s Vision 2030, a comprehensive framework aimed at diversifying the nation’s economy and reducing its dependence on oil. A core component of this vision is the development of sustainable, high-tech infrastructure. By integrating electric aviation into its transport network, the Kingdom aims to position itself as a leader in the Advanced Air Mobility (AAM) sector. This partnership brings together the requisite technology, operational expertise, and infrastructure to make zero-emission air travel a reality in the region.

Initial operations are slated to focus on the western coast of the Kingdom, specifically within the regenerative tourism destinations developed by Red Sea Global. These areas, known for their focus on environmental preservation and luxury, present a unique use case for quiet, electric aircraft. The transition from traditional combustion-engine helicopters to electric alternatives aligns with the broader environmental goals of the region, offering a glimpse into the future of sustainable tourism transport.

The “Sandbox” Program and Operational Framework

The collaboration utilizes a “sandbox” approach, which is essential for the safe integration of novel aviation technologies. This program allows the partners to conduct real-world test flights of Archer’s “Midnight” aircraft in a specific, controlled zone. The data gathered during these operations will be instrumental in validating safety protocols, assessing infrastructure readiness, and refining regulatory frameworks. It serves as a bridge between theoretical planning and commercial application, ensuring that all systems are robust before the service is opened to the general public.

The Helicopter Company (THC) plays a central role as the operator in this equation. Established by the PIF in 2019, THC is the Kingdom’s premier commercial helicopter operator. By leveraging its existing operational infrastructure and regulatory standing, THC provides the backbone for this new service. Their involvement suggests a seamless integration of eVTOLs into the existing airspace management systems, utilizing their experience to oversee the fleet of Archer aircraft. This operational stability is crucial for building public trust in pilot-plus-passenger electric flight.

Red Sea Global (RSG) provides the physical destination and the immediate commercial use case. As the developer behind “giga-projects” such as The Red Sea and Amaala, RSG is creating destinations that run entirely on renewable energy. The introduction of electric air taxis replaces the need for traditional ground transport or noisy helicopters, thereby preserving the tranquility of these luxury resorts. RSG will facilitate the construction of vertiports, specialized takeoff and landing pads, necessary to support the Midnight aircraft’s operations.

“Partnering with THC and Archer… aligns perfectly with our vision for regenerative tourism, creating cleaner, faster, and more connected ways for guests to experience the beauty of Saudi Arabia.” , John Pagano, CEO, Red Sea Global.

Technical Specifications of the Archer “Midnight”

The aircraft at the center of this initiative is Archer’s “Midnight,” a piloted, four-passenger eVTOL designed specifically for rapid, sustainable short-haul travel. The technical specifications of the Midnight are tailored to meet the demands of high-frequency urban and regional transport. It features a range of approximately 100 miles (160 km), though it is optimized for back-to-back trips of around 20 miles. This operational profile is well-suited for connecting resorts, airports, and city centers within the Red Sea development zone.

Speed and efficiency are critical factors for the adoption of this technology. The Midnight is capable of reaching speeds up to 150 mph (241 km/h), significantly reducing travel time compared to ground transportation. Furthermore, the aircraft is designed for rapid turnaround times, with a charging cycle of approximately 10 to 12 minutes. This capability allows for continuous operations with minimal downtime between flights, a necessary feature for a commercially viable air taxi service.

One of the most significant advantages of the Midnight aircraft in a luxury tourism context is its acoustic profile. The aircraft is engineered to be significantly quieter than a traditional helicopter, registering approximately 45 dBA at cruising altitude. In destinations where silence and immersion in nature are key selling points, the reduction of noise pollution is a critical operational requirement. The safety architecture includes distributed electric propulsion with 12 independent motors and propellers, providing redundancy that ensures the aircraft can maintain flight even in the event of a motor failure.

Regulatory Alignment and Vision 2030

The regulatory environment in Saudi Arabia is evolving rapidly to accommodate these new technologies. The General Authority of Civil Aviation (GACA) is the primary regulator overseeing the initiative and has launched a specific Advanced Air Mobility (AAM) Roadmap. A key aspect of this roadmap is GACA’s decision to validate certification standards from the US Federal Aviation Administration (FAA). This alignment streamlines the approval process for US-based manufacturers like Archer, removing the need for redundant certification hurdles and accelerating the timeline for deployment.

This partnership is not merely a commercial endeavor but a strategic enabler of Vision 2030. The Kingdom aims to attract 150 million visitors by 2030, and the aviation sector is targeted to contribute $75 billion to the GDP. By localizing eVTOL operations, Saudi Arabia is fostering an ecosystem that creates high-tech jobs and attracts foreign investment. The commitment to sustainability is equally aggressive, with RSG aiming to be “net positive.” The deployment of zero-emission aircraft is a tangible demonstration of this commitment, moving beyond carbon offsets to actual carbon reduction.

While Archer has secured this strategic foothold with RSG, the landscape remains competitive. Other entities, such as Joby Aviation and Lilium, are also active in the region, pursuing partnerships with different Saudi stakeholders. However, Archer’s focus on the luxury tourism sector through RSG provides a distinct entry point. Rather than immediately tackling complex urban air mobility in dense cities, launching in a controlled, private tourism environment allows for a high-visibility rollout with managed variables.

“We look forward to working together to demonstrate how Archer’s Midnight aircraft can transform travel within the Kingdom and set a regional benchmark for the future of aviation.” , Adam Goldstein, CEO, Archer Aviation.

Concluding Perspectives

The collaboration between Archer Aviation, The Helicopter Company, and Red Sea Global represents a concrete step toward the realization of advanced air mobility in the Middle East. By combining US aerospace technology with Saudi operational infrastructure and real estate development, the partnership addresses the three critical pillars of AAM: the aircraft, the operator, and the infrastructure. The “sandbox” program will provide the necessary data to prove the viability of these systems in desert conditions and regulatory environments.

As the project moves from testing to commercialization, it serves as a case study for how emerging technologies can be integrated into national development strategies. If successful, this initiative could set a precedent for sustainable tourism transport globally, proving that luxury travel and environmental stewardship can coexist through technological innovation.

FAQ

What is the primary goal of the partnership between Archer, THC, and RSG?
The goal is to launch electric vertical takeoff and landing (eVTOL) air mobility services in Saudi Arabia, starting with a controlled “sandbox” testing program at Red Sea Global destinations.

What aircraft will be used for these operations?
The operations will utilize Archer Aviation’s “Midnight” aircraft, a piloted eVTOL capable of carrying four passengers.

Why is the “Midnight” aircraft suitable for luxury tourism?
The Midnight is designed to be significantly quieter than helicopters (approx. 45 dBA at cruise) and produces zero operating emissions, aligning with the environmental and noise standards of luxury resorts.

Sources

• Archer Aviation Press Release