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.
GKN Aerospace Delivers High-Voltage EWIS for SWITCH Project: A Leap Toward Sustainable Aviation
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.
Technological Innovations in High-Voltage EWIS
Next-Generation Materials and Design
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
Challenges in Certification and Integration
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: Architecture and Industry Impact
Hybrid-Electric Propulsion System
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.
Performance Targets and Timeline
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
Conclusion: Toward a Climate-Neutral Future
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.
FAQ
What is EWIS and why is it important?
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.
What makes GKN’s high-voltage EWIS unique?
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.
When will hybrid-electric aircraft using SWITCH technology enter service?
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.
Sources: GKN Aerospace, CORDIS, FAA, Airbus, Collins Aerospace, MTU Aero Engines, Pratt & Whitney Canada
Photo Credit:
Sustainable Aviation
U.S. Advances Sustainable Aviation Fuel Initiative with 2030 Targets
U.S. agencies collaborate to scale sustainable aviation fuel production to 3 billion gallons by 2030, aiming to cut emissions and boost energy security.
This article is based on an official press release from the U.S. Department of Energy.
U.S. Government Accelerates Sustainable Aviation Fuel Initiative to Meet 2030 Goals
The push to decarbonize the aerospace sector is entering a critical execution phase. Through a formalized Memorandum of Understanding (MOU), the U.S. Department of Energy (DOE), the Department of Transportation (DOT), and the Department of Agriculture (USDA) have united to drive the Sustainable Aviation Fuel (SAF) Initiative. Originally launched in September 2021 as the SAF Grand Challenge, this government-wide effort aims to scale up domestic production, enhance national energy security, and revitalize rural agricultural economies.
Sustainable aviation fuel is a synthesized, “drop-in” hydrocarbon fuel derived from renewable or waste materials rather than traditional petroleum. Because it requires no modifications to existing aircraft engines or fueling infrastructure, federal agencies and industry leaders view it as the most viable near-term solution for reducing aviation emissions. According to the DOE, the initiative targets a minimum 50% reduction in lifecycle greenhouse gas emissions compared to conventional jet fuel.
As we move through 2026, the transition from foundational planning to active infrastructure expansion is well underway. With ambitious production targets looming at the end of the decade, the coordinated federal strategy is deploying hundreds of millions in grant funding to bridge the gap between current supply and future demand.
Core Objectives and Federal Investments
Time-Bound Production Targets
The SAF Initiative is anchored by two primary production milestones. According to official DOE and DOT frameworks, the near-term objective is to scale domestic SAF production to 3 billion gallons per year by 2030. Looking further ahead, the long-term goal is to produce enough SAF to meet 100% of domestic aviation fuel demand by 2050, a figure the agencies estimate will reach approximately 35 billion gallons annually.
Biomass Potential and Feedstock Diversity
To meet these massive volume requirements, the initiative relies on a diverse array of approved feedstocks, including corn grain, oil seeds, forestry residues, municipal solid waste, and agricultural byproducts. Data from the DOE’s 2023 Billion-Ton Report indicates that the United States possesses the capacity to triple its biomass production to over 1 billion tons per year. The DOE projects that this volume could yield an estimated 60 billion gallons of liquid biofuels, providing more than enough raw material to satisfy the 2050 aviation demand projections.
Infrastructure and Grant Funding
Federal financial backing has been crucial to moving these targets from paper to production. In January 2025, the Federal Aviation Administration (FAA) announced $249 million in grants through the Fueling Aviation’s Sustainable Transition (FAST) program. This capital injection, funded by a $297 million appropriation to the DOT under the Inflation Reduction Act, is specifically earmarked for domestic SAF production, transportation, and storage infrastructure.
These investments are already yielding tangible geographic expansions. Historically, U.S. SAF supply networks were heavily concentrated on the West Coast. However, federal progress reports note that by early 2025, new supply terminals successfully reached the U.S. East Coast, significantly broadening access for commercial and private aviation hubs nationwide.
“Over the past three years, as this Department has worked alongside our partners in the administration and in the private sector, we’ve made measurable progress in reducing emissions and making our skies cleaner while also growing the economy and creating good-paying jobs.”
Commercial Adoption and Global Context
Airlines Ramp Up Utilization
Commercial airlines are the ultimate end-users of this federal push, and recent data shows a marked increase in adoption, despite ongoing supply constraints. In April 2026, Delta Air Lines reported consuming 23.4 million gallons of SAF throughout 2025. According to the airline’s sustainability disclosures, this represents an 80% increase from the 13 million gallons utilized in 2024.
“Delta’s goal of using 10% SAF by 2030 remains real. Every day, we’re working across our business, industry and the SAF value chain for meaningful impact – and we’re making solid progress.”
International Regulatory Momentum
The U.S. SAF Initiative does not exist in a vacuum; it operates alongside tightening global regulations. In 2025, the European Union’s ReFuelEU Aviation mandate took effect, legally requiring fuel suppliers to blend a minimum percentage of SAF at EU airports. Concurrently, the International Civil Aviation Organization (ICAO) has established a global framework targeting a 5% reduction in the carbon intensity of international aviation fuels by 2030. These international pressures ensure that U.S. airlines operating globally must secure reliable SAF supply chains to remain compliant.
AirPro News analysis
We observe that the narrative surrounding the SAF Initiative has fundamentally shifted over the past two years. While the 2021 Grand Challenge was primarily framed around climate goals and decarbonization, the 2026 landscape, highlighted by reports like the World Economic Forum’s Global Aviation Sustainability Outlook 2026, positions SAF equally as a matter of national energy security. By utilizing domestic agricultural and municipal waste, the U.S. is actively attempting to insulate its aviation sector from volatile foreign oil markets.
However, significant hurdles remain. While Delta’s 80% year-over-year usage increase is commendable, 23.4 million gallons is a drop in the bucket compared to the 3-billion-gallon target set for 2030. The January 2025 SAF Grand Challenge Progress Report and the November 2024 Roadmap Implementation Framework both acknowledge persistent gaps in technology scaling and supply chain logistics. For the DOE, DOT, and USDA, the next four years will be a race against time to ensure that feedstock processing and refinery capacities can match the aggressive timelines they have mandated.
Frequently Asked Questions (FAQ)
- What is Sustainable Aviation Fuel (SAF)?
SAF is a renewable, “drop-in” alternative to conventional petroleum-based jet fuel. It is synthesized from waste materials, biomass, and agricultural residues, and can be used in existing aircraft without engine modifications. - What are the primary goals of the U.S. SAF Initiative?
The initiative aims to achieve a 50% reduction in lifecycle greenhouse gas emissions, produce 3 billion gallons of SAF annually by 2030, and scale up to 35 billion gallons by 2050 to meet 100% of domestic aviation demand. - Which federal agencies are leading this effort?
The initiative is a collaborative effort governed by a Memorandum of Understanding between the Department of Energy (DOE), the Department of Transportation (DOT), and the Department of Agriculture (USDA). - How is the government funding this transition?
Funding is being deployed through various channels, notably including $249 million in FAA FAST program grants announced in January 2025, which were funded by the Inflation Reduction Act.
Sources: U.S. Department of Energy
Photo Credit: U.S. Department of Energy
Sustainable Aviation
AeroDelft Conducts First Hydrogen Aircraft Taxi Tests in Netherlands
AeroDelft’s student team completed the first hydrogen-powered aircraft taxi tests at Rotterdam The Hague Airport, advancing sustainable aviation.
This article is based on an official press release from AeroDelft.
In late May 2026, the student-led engineering team AeroDelft achieved a significant milestone in sustainability aviation. According to an official press release from the organization, the team successfully conducted the first-ever taxi tests of a hydrogen-powered aircraft at an operational airport in the Netherlands. The tests took place at Rotterdam The Hague Airport (RTHA) and represent a critical transition from laboratory research to real-world application.
The comprehensive testing phase included hydrogen refueling operations, powertrain evaluations, and active taxi tests using gaseous hydrogen. By executing these procedures in a live commercial airport environment, AeroDelft and its partners gathered essential data on both the aircraft’s technological performance and the operational protocols required to safely handle hydrogen on an active tarmac.
This achievement is the culmination of extensive engineering and preparation. As noted in the team’s announcement, bringing a hydrogen aircraft to an operational airport required rigorous safety analyses, detailed operational planning, and close collaboration among multiple aviation and energy stakeholders.
Advancing Project Phoenix
From Laboratory to Tarmac
AeroDelft, a non-profit foundation run entirely by Delft University of Technology (TU Delft) students, has been developing “Project Phoenix” since 2018. According to supplementary research data, the initiative focuses on converting a Sling 4 airframe into a manned hydrogen-electric aircraft. Industry research highlights that in May 2025, AeroDelft became the first student team globally to test a full liquid hydrogen propulsion system in a lab setting, working alongside the Netherlands Organization for Applied Scientific Research (TNO).
Safety and Operational Planning
Operating an experimental aircraft at a commercial facility demands strict safety measures. According to project data, AeroDelft developed comprehensive risk analyses and an operational taxi test plan. This was achieved in close collaboration with research test pilots Alexander in ‘t Veld and Hans Mulder from TU Delft’s Flight Test Laboratory, ensuring that the live tests at RTHA’s Fieldlab Next Aviation facility met stringent aviation safety standards.
Technical Specifications and Infrastructure
Gaseous vs. Liquid Hydrogen
The recent taxi tests utilized gaseous hydrogen. While AeroDelft’s ultimate objective is to achieve flight using liquid hydrogen, gaseous hydrogen was selected for this phase due to its current technological maturity. Based on technical specifications provided in the research report, the single-seat converted aircraft uses a hydrogen fuel cell that combines hydrogen and oxygen to generate electricity, emitting only water. With a full tank of gaseous hydrogen, the aircraft is projected to have an endurance of approximately 40 minutes.
Transitioning to liquid hydrogen remains the next major technical hurdle. Because liquid hydrogen offers a significantly higher energy density by mass and volume, the team projects that utilizing liquid fuel will extend the aircraft’s flight endurance to approximately two hours. To achieve this, future development will require the integration of a cryogenic storage tank capable of maintaining temperatures at -253 °C, along with a complex distribution system.
The DutcH₂ Aviation Hub
The successful test campaign was facilitated by the DutcH₂ Aviation Hub, a collaborative ecosystem coordinated by the Rotterdam The Hague Innovation Airport (RHIA) Foundation and funded by the City of Rotterdam. The AeroDelft press release explicitly thanked partners including TU Delft Aerospace Engineering, RTHA, RHIA, and Air Products Benelux for their roles in turning months of preparation into a successful live test.
Perspectives on Sustainable Aviation
The transition to zero-emission aviation requires proving that new technologies are viable outside of controlled environments. Isha Moharir, Team Manager at AeroDelft, emphasized the importance of real-world testing in public remarks cited by industry reports:
“We want to demonstrate that flying on hydrogen works and that it’s safe in the air and at the airport… We are making absolutely no concessions on safety.”
Moharir further noted that testing at an operational commercial airport yields invaluable insights into the practical steps needed for sustainable aviation. Similarly, Daan van Dijk, an innovator at Rotterdam The Hague Airport, stated that these tests demonstrate tangible progress. According to research summaries, van Dijk highlighted that testing at an active airport is the exact method by which the aviation industry will learn to safely scale hydrogen-powered flight.
AirPro News analysis
We observe that while much of the aerospace sector’s attention has been focused on the in-flight capabilities of hydrogen aircraft, the logistical realities on the ground present an equally formidable challenge. The AeroDelft taxi tests at Rotterdam The Hague Airport serve as a crucial proof-of-concept for bridging the infrastructure gap. Traditional airports are optimized for kerosene; introducing hydrogen requires entirely new storage facilities, mobile refuelers, and emergency response protocols.
Furthermore, the broader hydrogen aviation race is accelerating. While battery-electric aviation propulsion shows promise for short-haul routes, the prohibitive weight of current battery technology limits its application for commercial passenger aviation. Liquid hydrogen presents a highly competitive alternative for longer ranges, provided that the cryogenic and logistical challenges, which initiatives like Project Phoenix are actively addressing, can be resolved at scale.
Frequently Asked Questions
What is Project Phoenix?
Project Phoenix is an initiative launched in 2018 by AeroDelft, a student-led team from TU Delft, aimed at developing a manned hydrogen-electric aircraft by converting a Sling 4 airframe.
Why did AeroDelft use gaseous hydrogen instead of liquid hydrogen for the taxi tests?
Gaseous hydrogen was used because it is currently a more mature and developed technology, allowing the team to safely test the powertrain and airport integration. The ultimate goal remains transitioning to liquid hydrogen for greater flight endurance.
Where did the taxi tests take place?
The tests were conducted at the Fieldlab Next Aviation facility located at Rotterdam The Hague Airport (RTHA) in the Netherlands.
Sources
- AeroDelft Official Press Release
- Supplementary Industry Research Report (Provided Data)
Photo Credit: AeroDelft
Sustainable Aviation
Loganair Signs 15-Year Sustainable Aviation Fuel Deal with ClimaHtech
Loganair secures a 15-year SAF supply agreement with ClimaHtech Green Flight, starting deliveries by 2029 to support UK SAF mandate compliance.
This article is based on an official press release from Loganair.
Loganair, the United Kingdom’s largest regional Airlines, has officially entered into a 15-year SAF offtake agreement with ClimaHtech Green Flight (CGF). According to the company’s press release, fuel deliveries under this new partnership are scheduled to commence by 2029. The agreement marks a significant step in the regional carrier’s strategy to secure a long-term fuel supply while navigating the evolving landscape of aviation emissions regulations.
The strategic partnership is designed to hedge against long-term fuel price volatility and mitigate compliance costs associated with the UK government’s SAF mandate. While the specific commercial value and volume metrics of the contract have not been publicly disclosed, the agreement insulates the airline from broader macroeconomic supply chain disruptions and high logistics costs.
A standout feature of this collaboration is CGF’s decentralized production model. Rather than relying on traditional, centralized mega-refineries, modular SAF production units will be deployed directly across Loganair’s primary operational network, which includes the Scottish Highlands, Islands, and other regional UK routes.
A Decentralized Approach to Sustainable Aviation Fuel
The partnership relies on highly innovative fuel production technology. ClimaHtech Green Flight, a wholly owned subsidiary of Belfast-based clean energy engineering company CATAGEN, will supply Loganair with fuel produced via two advanced pathways: BioSAF (Power-Biomass-to-Liquid) and eSAF (Power-to-Liquid).
According to the provided technical details, CGF utilizes patented modular reactor technology, specifically the BIOHGEN and E-FUEL GEN systems developed by CATAGEN. This electrically driven platform can operate alongside intermittent renewable power assets and utilize waste biomass feedstocks. Each modular unit is capable of producing 1 million liters of SAF per year, delivering an estimated 90% reduction in well-to-wing carbon emissions compared to conventional fossil jet fuel.
Overcoming Regional Logistics Challenges
As a regional carrier, Loganair operates numerous routes that serve as essential lifelines for remote communities rather than luxury travel destinations. Decarbonizing these short-haul flights presents unique logistical challenges. By deploying production infrastructure close to the point of consumption across Northern Ireland and Scotland, the decentralized model eliminates the need to ship fuel from a distant central hub, thereby reducing both transportation costs and associated carbon emissions.
Regulatory Pressures and Industry Context
The agreement is heavily driven by the current regulatory landscape in the United Kingdom. The UK SAF mandate officially entered into force on January 1, 2025. The mandate requires jet fuel suppliers to blend alternative aviation fuel into conventional aviation fuel at increasing concentrations. The requirement started at 2% in 2025, will rise to 10% by 2030, and is set to reach 22% by 2040. Securing a 15-year supply helps Loganair ensure compliance and avoid potential future market shortages.
ClimaHtech Green Flight, launched in September 2025 at CATAGEN’s Titanic Quarter Campus in Belfast, was created to disrupt the SAF market using off-grid renewable and low-carbon electricity sources. The company has already secured strategic partnerships and offtake agreements with other major industry players, including Ryanair and Shell Aviation Ireland Limited.
Executive Perspectives
Company leadership emphasized the importance of localizing fuel production to support regional connectivity.
“As the UK’s largest regional airline, Loganair plays a vital role in connecting communities across the UK, particularly in areas where aviation is a lifeline rather than a luxury. Decarbonising regional aviation is therefore both a responsibility and a practical challenge. This long-term agreement with ClimaHtech Green Flight is an important step in securing access to Sustainable Aviation Fuel that is produced closer to where we operate, supports UK supply chains, and reflects our commitment to lower our carbon footprint.”
“This offtake agreement with Loganair demonstrates strong airline confidence in our SAF pathways and our ambition to build a distributed, regional SAF production model.”
AirPro News analysis
We view this agreement as a critical indicator of how regional airlines are adapting to stringent environmental mandates. A major hurdle for SAF adoption globally has been the cost and carbon footprint of transporting the fuel from centralized refineries to regional airports. CGF’s decentralized model could serve as a blueprint for regional airlines worldwide, solving the logistics bottleneck that often plagues smaller carriers.
Furthermore, by utilizing local waste biomass and renewable energy, the UK aviation sector can reduce its reliance on imported fuels. This aligns with broader national energy security goals. With the UK SAF mandate now active, airlines are in a race to secure affordable SAF. Early movers like Loganair are locking in long-term Contracts to avoid the anticipated price spikes as the mandate percentages increase toward 2030.
Frequently Asked Questions (FAQ)
When will Loganair begin receiving SAF under this agreement?
Fuel Deliveries from ClimaHtech Green Flight are scheduled to commence by 2029.
How much SAF can the modular units produce?
Each modular unit from CGF is capable of producing 1 million liters of SAF per year.
What are the UK SAF mandate requirements?
The mandate requires a 2% SAF blend starting in 2025, increasing to 10% by 2030, and reaching 22% by 2040.
Sources
Photo Credit: Loganair
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