Sustainable Aviation
GKN Aerospace Advances Hybrid-Electric Aviation with EU SWITCH Project
GKN’s high-voltage EWIS system enables 75% lower climate impact for hybrid-electric aircraft, backed by EU’s €1.7B Clean Aviation initiative.
The aviation industry stands at a critical juncture, facing mounting pressure to reduce its environmental footprint while maintaining operational efficiency and safety. In this context, the recent delivery of a high-voltage Electrical Wiring Interconnection System (EWIS) by GKN Aerospace for the European Union’s Clean Aviation SWITCH project marks a significant technological and environmental milestone. This development supports the transition toward hybrid-electric propulsion, aligning with the EU’s broader goal of achieving climate-neutral aviation by 2050.
GKN’s EWIS, developed at its Papendrecht facility, is designed to transmit megawatt-class electrical power, a necessity for hybrid propulsion systems. The SWITCH project integrates dual-spool hybrid-electric architecture and water-enhanced turbofan (WET) technology, aiming to improve energy efficiency by 25% and reduce climate impact by 75% when using net-zero CO₂ sustainable aviation fuels (SAFs). Backed by a €1.7 billion EU investment, this initiative is a cornerstone of Europe’s clean aviation roadmap.
GKN Aerospace’s EWIS incorporates several first-in-industry features that address the stringent requirements of hybrid-electric aircraft. The harness systems utilize graphene-doped insulation, which offers 30% better thermal conductivity compared to traditional PTFE materials. This improvement is crucial for maintaining system integrity in high-temperature zones near engines, where temperatures can exceed 300°C.
Another innovation lies in the use of shape-memory polymers for dynamic cable management. These materials allow conduits to auto-adjust in response to thermal expansion, ensuring consistent cable tension and reducing mechanical stress on connectors. Anti-vibration mounts further stabilize the system during high-G moments such as takeoff and climb.
On the monitoring front, each harness includes a distributed temperature sensing grid with over 1,000 fiber optic sensors. These sensors provide real-time thermal maps, enabling predictive maintenance and early detection of hotspots. Additionally, the system features partial discharge detection capable of identifying arc precursors at sensitivity levels below 10 picoCoulombs.
“Our Trollhättan test rig’s 20MW capacity enables simultaneous validation of thermal and electrical loads, a prerequisite for megawatt-class EWIS.” , Henrik Runnemalm, VP, GKN Aerospace
Developing a high-voltage EWIS for aviation is not without its challenges. One of the primary hurdles is partial discharge mitigation. The system must handle sub-nanosecond voltage rise times, with dV/dt rates exceeding 10kV/μs. To combat this, GKN employs nitrogen-filled conduit cavities and self-healing dielectrics that can repair minor insulation breaches autonomously.
Thermal management is another critical area. The EWIS uses a two-phase evaporative cooling system capable of removing up to 5kW per meter of heat load. Directional heat pipes conduct up to 150W/cm² from high-current lugs, ensuring that thermal stresses do not compromise performance or safety.
Electromagnetic compatibility (EMC) is addressed through triple-shielded twisted pairs and common-mode chokes. These components help achieve signal attenuation of up to 100dB at 1GHz and reduce leakage currents to below 1mA, which is essential for maintaining avionics reliability in megawatt-scale systems. The SWITCH project’s propulsion system integrates three key technologies: a dual-spool hybrid configuration, a water-enhanced turbofan (WET), and a high-voltage power distribution network. The high-pressure spool includes a 500kW derated motor generator, while the low-pressure spool features a 1MW primary motor. Together, these components support electric taxiing, takeoff boost, and waste heat recovery, capturing up to 40% of thermal energy from exhaust gases.
The WET system recycles up to 70% of combustion byproduct water, reinjecting it into the combustion chamber to cool the flame and reduce NOx emissions by 50%. Additionally, particle filtration within the WET architecture reduces contrail formation by 75%, addressing another significant contributor to aviation’s climate impact.
The electrical backbone operates at 1,200V DC, which is 50% lighter than equivalent AC systems. Solid-state protection mechanisms using silicon carbide (SiC) switches offer microsecond-range fault isolation, enhancing safety and reliability.
The SWITCH project is structured around a phased validation approach. Ground testing of the integrated EWIS began in 2025 at Collins Aerospace’s Grid facility. The project aims to achieve Technology Readiness Level (TRL) 4 for the WET engine and TRL 5 for the Electrical Aircraft Propulsion (EAP) system by 2025. Flight tests on modified Airbus A320neo platforms are planned for 2030, with entry into service for short- and medium-haul aircraft targeted for 2035.
Key performance metrics include a 25% improvement in fuel efficiency and a 75% reduction in climate impact when using net-zero CO₂ SAFs. These figures represent a significant leap from current baselines and position SWITCH as a leader in sustainable aviation innovation.
Such ambitious targets require robust cross-industry collaboration. Partners like MTU Aero Engines, Airbus, and Collins Aerospace contribute expertise in propulsion, integration, and power electronics, creating a synergistic environment for rapid technological advancement.
“SWITCH technologies could eliminate 850 million tons of CO₂ by 2050, equivalent to 2% of global aviation emissions.” , Sabine Klauke, CTO, Airbus
The delivery of GKN Aerospace’s high-voltage EWIS for the SWITCH project is more than a technical achievement, it’s a roadmap toward climate-neutral aviation. By enabling megawatt-class power transmission with reduced weight and enhanced safety, this innovation supports the viability of hybrid-electric aircraft for commercial use by 2035.
However, the path forward is complex. Achieving net-zero aviation will require parallel developments in sustainable aviation fuels, hydrogen infrastructure, and recycling of high-voltage components. Continued collaboration between OEMs, regulators, and suppliers, supported by EU funding and international standards, will be essential to realizing these goals. What is EWIS and why is it important? What makes GKN’s high-voltage EWIS unique? When will hybrid-electric aircraft using SWITCH technology enter service? Sources: GKN Aerospace, CORDIS, FAA, Airbus, Collins Aerospace, MTU Aero Engines, Pratt & Whitney Canada
GKN Aerospace Delivers High-Voltage EWIS for SWITCH Project: A Leap Toward Sustainable Aviation
Technological Innovations in High-Voltage EWIS
Next-Generation Materials and Design
Challenges in Certification and Integration
The SWITCH Project: Architecture and Industry Impact
Hybrid-Electric Propulsion System
Performance Targets and Timeline
Conclusion: Toward a Climate-Neutral Future
FAQ
EWIS stands for Electrical Wiring Interconnection System. It is critical for power distribution, data transmission, and system control in aircraft. In hybrid-electric systems, EWIS must handle higher voltages and power levels, making innovation in this area essential for future aviation.
GKN’s EWIS features graphene-doped insulation, shape-memory polymers, and advanced thermal and electromagnetic shielding. These innovations allow it to handle megawatt-class power while maintaining safety and reliability.
According to the SWITCH project timeline, hybrid-electric aircraft are expected to enter commercial service by 2035, with flight testing on modified Airbus A320neo platforms beginning in 2030.
Photo Credit:
Sustainable Aviation
Asia-Pacific Aviation Growth and Sustainable Aviation Fuel Initiatives 2026
Asia-Pacific aviation growth faces decarbonization challenges with new SAF mandates and Airbus’s just transition strategy at Singapore Airshow 2026.
This article is based on an official press release from Airbus and additional industry reporting regarding the Singapore Airshow 2026.
As the aviation industry gathers for the Singapore Airshow 2026, the Asia-Pacific (APAC) region stands as the focal point of global aerospace growth. According to recent industry forecasts, APAC is projected to account for over 50% of global aviation growth between 2025 and 2026. However, this rapid expansion presents a critical challenge: reconciling a forecast 7.3% increase in passenger traffic with urgent decarbonization goals.
In a press release issued on February 2, 2026, Airbus outlined a strategy focused on a “just transition.” The European manufacturer argues that the adoption of Sustainable Aviation Fuel (SAF) in Asia-Pacific offers more than just environmental compliance; it presents a pathway for regional socioeconomic development and energy sovereignty.
While the primary driver for SAF adoption globally has been carbon reduction, Airbus emphasizes that for the APAC region, the benefits are deeply tied to local economic resilience. The region possesses abundant feedstock potential, including agricultural residues, used cooking oil, and palm oil waste.
According to the Airbus announcement, utilizing agricultural waste for fuel production addresses multiple local issues simultaneously. In many parts of Asia, the burning of agricultural fields contributes significantly to seasonal air pollution. By converting this biomass into SAF, the region can reduce local smog while creating new revenue streams for rural communities.
Airbus describes this approach as a “just transition,” ensuring that the shift to green energy supports developing economies rather than hindering them. The manufacturer notes that developing local production capabilities also boosts “regional energy sovereignty,” reducing the reliance on imported fossil fuels.
“Given the broad socioeconomic diversity… Asia-Pacific is a prime place to demonstrate the possibilities for a just transition. Leveraging co-benefits could open opportunities to build community resilience.”
, Airbus Press Release, February 2, 2026
Beyond manufacturer initiatives, government policy in the region is hardening. Data released in conjunction with the Singapore Airshow highlights a wave of new mandates and targets aimed at accelerating SAF uptake. Most notably, Singapore has confirmed the introduction of a SAF levy for all flights departing from Changi Airport starting October 1, 2026. This levy is designed to fund a national 1% SAF target by the end of the year, with plans to scale to 3-5% by 2030.
Other regional developments include:
The push for decarbonization is also visible on the tarmac. During the Singapore Airshow, an Airbus A350-1000 is performing flying displays powered by a 35% SAF blend. The fuel, supplied by Shell Aviation, was produced via the HEFA-SPK pathway using used cooking oil and tallow.
In a significant move for propulsion technology, Airbus, CFM International, and the Civil Aviation Authority of Singapore (CAAS) signed a Memorandum of Understanding (MOU) on February 2. This agreement establishes Singapore as the world’s first airport testbed for the “RISE” (Revolutionary Innovation for Sustainable Engines) program. The initiative aims to test “Open Fan” engine architecture, which targets a 20% improvement in fuel efficiency.
Additionally, Airbus and Cathay Group have reiterated their commitment to a US$70 million joint investment, originally announced in late 2025, to accelerate SAF production projects with commercial viability in the region.
While the regulatory and technological momentum is palpable, a stark reality remains. Industry data indicates that global SAF output reached only 1.9 million tonnes in 2025, representing a mere 0.6% of total jet fuel demand. With APAC passenger traffic expected to grow by 7.3% in 2026, the gap between demand for travel and the supply of green fuel is widening.
The “green premium”, where SAF costs 2x to 4x more than conventional jet fuel, remains the primary hurdle. While the “just transition” narrative provided by Airbus offers a compelling long-term vision for feedstock utilization, the immediate success of these initiatives will depend heavily on whether the new levies and investments can bridge the price gap quickly enough to meet the 2027-2030 mandates.
What is the “Just Transition” in aviation? When does the Singapore SAF levy begin? What is the current global supply of SAF? Sources:
Asia-Pacific Aviation at a Crossroads: Balancing Growth with a “Just Transition”
The Socioeconomic Case for SAF
Turning Waste into Wealth
Regulatory Momentum and National Mandates
Technological Milestones at Singapore Airshow 2026
New Partnerships
AirPro News Analysis
Frequently Asked Questions
In this context, it refers to decarbonizing aviation in a way that provides economic benefits to developing nations, such as creating jobs in rural areas by using agricultural waste for fuel production.
The levy applies to all flights departing Singapore starting October 1, 2026.
As of 2025, SAF production accounted for approximately 0.6% of total global jet fuel usage.
Airbus,
IATA,
Civil Aviation Authority of Singapore
Photo Credit: Airbus
Sustainable Aviation
FedEx Expands Sustainable Aviation Fuel Program to DFW and JFK Airports
FedEx expands sustainable aviation fuel use to Dallas-Fort Worth and JFK airports, supporting its carbon-neutral goals with 5 million gallons secured for 2025.
This article is based on an official press release from FedEx.
FedEx has officially expanded its SAF program to include Dallas-Fort Worth International Airport (DFW) and John F. Kennedy International Airport (JFK). The logistics giant announced the move on January 29, 2026, marking a significant step in its “Priority Earth” sustainability roadmap. With these additions, FedEx now utilizes SAF at five airports across the United States.
According to the company’s announcement, the expansion is supported by World Fuel Services (WFS), which manages the supply chain and delivery of the fuel. The initiative positions FedEx as the first airline, cargo or passenger, to purchase SAF for regular commercial operations at DFW, a major global logistics hub.
The agreement covers the purchase of approximately 2 million gallons of “neat” (unblended) SAF for these two locations. When combined with agreements for other hubs, FedEx has secured a total of 5 million gallons of neat SAF for delivery throughout 2025.
While the purchasing agreements are calculated in gallons of “neat” SAF, the fuel actually delivered to aircraft is a blend. Safety regulations currently prohibit the use of 100% SAF in commercial aircraft engines. Consequently, the fuel supplied to FedEx at DFW and JFK is a mixture containing a minimum of 30% neat SAF blended with conventional Jet A fuel.
World Fuel Services facilitates this supply, typically sourcing the renewable component from Valero’s Diamond Green Diesel (DGD) joint venture. The SAF is produced via the HEFA (Hydroprocessed Esters and Fatty Acids) pathway, utilizing waste-based feedstocks such as used cooking oil, animal tallow, and distiller’s corn oil. This production method allows for a lifecycle greenhouse gas (GHG) emissions reduction of up to 80% compared to standard petroleum-based jet fuel.
In a statement regarding the logistical achievement, Bradley Hurwitz, Senior Vice President of Supply & Trading at World Fuel Services, noted:
“FedEx’s purchase at DFW and JFK demonstrates how our aviation fuel distribution platform enables carriers to access lower-carbon fuel options with a robust supply chain designed for flexibility and scale.”
This expansion is part of FedEx’s broader strategy to achieve carbon-neutral global operations by 2040. The company has set an interim target to source 30% of its total jet fuel from alternative fuels by 2030. The addition of DFW and JFK complements existing SAF programs at Los Angeles International Airport (LAX), Chicago O’Hare (ORD), and Miami International Airport (MIA). Karen Blanks Ellis, Chief Sustainability Officer at FedEx, emphasized the progress made over the last year:
“Expanding SAF use by FedEx to include our operations at DFW and JFK caps off a successful year of SAF deployments coast-to-coast. While we know there remains work ahead to procure more SAF… we are proud of our steps forward.”
The introduction of SAF at Dallas-Fort Worth is particularly notable. While pilot programs have existed at DFW since 2021, they were largely limited to business aviation. FedEx’s commitment marks the first regular commercial adoption at the airport, signaling a shift from experimental to operational use in the cargo sector.
However, the industry faces significant headwinds. SAF currently trades at a premium of two to five times the price of conventional jet fuel. Furthermore, global production remains less than 1% of total jet fuel demand. While the “book and claim” system and government incentives like the U.S. Inflation Reduction Act help bridge the cost gap, the physical availability of SAF remains the primary bottleneck for large-scale adoption.
By securing 5 million gallons of neat SAF for 2025, FedEx is signaling consistent demand to producers, which is essential for stimulating the investment required to increase production capacity.
Airport officials have welcomed the move as a validation of existing infrastructure capabilities. Because the blended fuel is a “drop-in” solution, it requires no modifications to airport storage tanks or hydration systems.
Robert Horton, Vice President of Environmental Affairs at DFW Airport, stated:
“FedEx’s SAF purchase reflects how airlines, airports, and fuel providers work together within existing airport infrastructure to support the development of more sustainable aviation operations.”
“Neat” SAF refers to the pure, unblended sustainable fuel. It is not used in aircraft in this form due to safety regulations. Instead, it is blended with conventional jet fuel before delivery. Purchasing agreements often cite “neat” volumes to track the exact amount of renewable content purchased.
As of early 2026, FedEx utilizes SAF at five U.S. airports: Dallas-Fort Worth (DFW), John F. Kennedy (JFK), Los Angeles (LAX), Chicago O’Hare (ORD), and Miami (MIA). The specific SAF used in this agreement, produced via the HEFA pathway, can reduce lifecycle greenhouse gas emissions by up to 80% compared to conventional jet fuel.
FedEx Expands Sustainable Aviation Fuel Program to DFW and JFK Airports
Operational Details and Supply Chain
Strategic Context: The “Priority Earth” Goal
AirPro News Analysis
Stakeholder Commentary
Frequently Asked Questions
What is “Neat” SAF?
Where does FedEx use SAF?
What is the emission benefit?
Sources
Photo Credit: FedEx
Sustainable Aviation
Washington Launches Cascadia Sustainable Aviation Accelerator for SAF
The Cascadia Sustainable Aviation Accelerator launches with $20M funding to boost Pacific Northwest Sustainable Aviation Fuel production to 1 billion gallons annually by 2035.
This article is based on official press releases from Alaska Airlines and Washington State University, as well as public announcements from the launch event.
On January 8, 2026, a coalition of government, industry, and academic leaders officially launched the Cascadia Sustainable Aviation Accelerator (CSAA). Unveiled at the Boeing Future of Flight in Mukilteo, Washington, the initiative aims to establish the Pacific Northwest as a global leader in the production and deployment of Sustainable Aviation Fuel (SAF).
According to official announcements, the accelerator is backed by $20 million in initial funding. This capital includes $10 million from Washington State’s Climate Commitment Act funds and a matching $10 million contribution from an anonymous philanthropic donor. The coalition has set an ambitious target: to scale regional SAF production to 1 billion gallons annually by 2035.
The initiative represents a broad partnership designed to bridge the gap between policy, technology, and commercial viability. Washington Governor Bob Ferguson championed the launch, positioning it as both an economic engine and a critical climate solution for the state.
The coalition features major stakeholders across multiple sectors:
“We have all the pieces in place to ensure this once-in-a-generation economic opportunity is realized, and this accelerator will make that happen.”
, Governor Bob Ferguson, via official press release
To address the complex barriers facing the SAF market, the initiative is divided into two complementary arms: the Accelerator and the Institute.
The CSAA focuses on market acceleration, financing, and policy advocacy. Its primary mission is to “de-risk” the industry for producers and investors. By harmonizing tax incentives and aggregating fuel demand from airlines and corporate partners, the Accelerator aims to create a stable market environment that encourages rapid scaling of production facilities. The Institute will handle the technical and scientific challenges of SAF adoption. It will operate a new Sustainable Aviation Fuel Research and Development Center based at Paine Field in Snohomish County. While a permanent facility is scheduled for completion by 2029, the center will open in a temporary commercial space in the coming months.
A key feature of the Institute will be the world’s first “SAF Repository.” This facility will function similarly to a seed bank, collecting, indexing, and distributing fuel samples to researchers globally to standardize testing and certification processes.
“For aviation to remain strong and resilient in the decades ahead, sustainability must be part of its future.”
, Elizabeth Cantwell, WSU President, via WSU News
Sustainable Aviation Fuel is widely considered the most viable near-term solution for decarbonizing long-haul aviation. Made from feedstocks such as agricultural waste, used cooking oil, or captured carbon, SAF can reduce lifecycle emissions by up to 80% compared to conventional jet fuel. However, current supply accounts for less than 1% of global jet fuel usage, and it remains significantly more expensive than fossil-based alternatives.
The Pacific Northwest is viewed as an ideal “test bed” for solving these problems due to its access to renewable hydroelectric power, forestry and agricultural residues, and a deep aerospace talent pool.
The Accelerator aims to support existing regional projects, including:
“This is a systems issue that no one company can solve. You’ve got great companies… ready to use this fuel, but we have to make it available.”
, Guy Palumbo, Amazon Director of Public Policy, via launch event remarks
The launch of the Cascadia Sustainable Aviation Accelerator marks a shift from individual corporate sustainability goals to a systemic regional strategy. While the target of 1 billion gallons by 2035 is aggressive, the bifurcation of the initiative into an “Accelerator” (finance/policy) and an “Institute” (R&D) suggests a mature understanding of the bottlenecks. The primary challenge for the CSAA will be feedstock logistics. While the Pacific Northwest has abundant forestry and agricultural waste, the infrastructure to collect, transport, and process these materials at a scale capable of producing 1 billion gallons does not yet exist. Furthermore, the involvement of corporate giants like Amazon and Microsoft is critical; their willingness to pay a “green premium” for sustainable air cargo and travel could provide the demand certainty that producers need to secure financing for new plants.
Success will likely depend on how quickly the Institute can streamline the fuel certification process, which has historically been a slow hurdle for new SAF pathways.
Sources:
Washington Leaders Launch Cascadia Sustainable Aviation Accelerator to Power PNW SAF Hub
A Public-Private Coalition
Strategic Structure: Accelerator and Institute
The Cascadia Sustainable Aviation Accelerator (CSAA)
The Cascadia Sustainable Aviation Institute (CSAI)
Industry Context and Regional Projects
AirPro News Analysis
Photo Credit: Alaska Airlines
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