GKN Aerospace and Archer Aviation Boost UK eVTOL Manufacturing

Forging the Future of Urban Air Mobility: GKN Aerospace and Archer Aviation Expand Partnership in the UK

The aerospace and urban mobility sectors are undergoing a transformative shift, as electric vertical takeoff and landing (eVTOL) aircraft edge closer to commercial viability. A key milestone in this journey was marked by the June 2025 announcement of an expanded collaboration between GKN Aerospace and Archer Aviation. This strategic partnership focuses on the manufacture of critical airframe components for Archer’s Midnight eVTOL aircraft at GKN’s UK facilities. The collaboration signifies more than a supply chain agreement, it reflects a broader industrial movement toward sustainable, scalable, and efficient urban air transportation.

With the global Advanced Air Mobility (AAM) market projected to grow significantly in the coming years, the GKN-Archer alliance positions the UK as a pivotal player in the race for zero-emission aviation. This partnership leverages GKN’s decades of aerospace manufacturing expertise and Archer’s innovative eVTOL platform to accelerate the industrialization of next-generation air travel. As cities worldwide seek to reduce congestion and carbon emissions, such collaborations are becoming essential in shaping the future of mobility.

Strategic Collaboration: Key Facts and Industrial Implications

Scope of the Expanded Partnership

Under the newly expanded agreement, GKN Aerospace will manufacture the wing structures for Archer’s Midnight aircraft using advanced composites and automation technologies. This builds upon GKN’s existing role in supplying the aircraft’s low-voltage Electrical Wiring Interconnection Systems (EWIS), previously produced at GKN’s Netherlands facility. The transition of manufacturing to the UK signals a strategic move to consolidate key production elements and support localized industrial growth.

The wing structures are critical not only for flight dynamics but also for achieving energy efficiency. GKN’s expertise in lightweight composite materials, used extensively in modern aircraft, plays a vital role in reducing the aircraft’s weight and, by extension, its emissions. The company’s high-rate manufacturing capabilities, including automated assembly lines, are expected to reduce assembly time, enabling a production ramp-up to meet Archer’s delivery targets.

This expansion supports Archer’s goal of scaling Midnight production to meet anticipated demand. The manufacturing process will take place at GKN’s UK facilities, which are equipped to handle the high precision and safety standards required for aviation-grade components. The collaboration also aligns with the UK government’s Aerospace Sector Deal, which allocated significant funding to future flight technologies, including eVTOL development.

“This collaboration accelerates the eVTOL industry’s shift from R&D to industrialization. Our composites and EWIS expertise will ensure Midnight meets the safety and sustainability demands of urban air mobility.” , John Pritchard, President, Civil Airframes, GKN Aerospace

Financial and Operational Metrics

The financial and operational scale of this partnership is substantial. GKN Aerospace’s UK operations currently employ a significant workforce, and the Midnight project is expected to create numerous high-skilled jobs by 2026. These roles will span engineering, composite manufacturing, and quality assurance, supporting the UK’s broader employment and innovation goals in aerospace.

From a market perspective, the eVTOL segment is forecasted to experience substantial growth by 2030, with urban air taxi services comprising a significant portion of that demand. Archer’s Midnight aircraft, with its range and cruising speed, is designed to meet this demand in congested urban corridors. The aircraft’s design includes multiple propellers and independent battery packs, emphasizing redundancy and safety.

Importantly, the partnership benefits from the UK’s long-term commitment to aerospace innovation. The Aerospace Technology Institute (ATI) Programme has invested billions in R&D since its inception, focusing on sustainable aviation technologies such as electrification and digital manufacturing. GKN’s involvement in this ecosystem ensures that the Midnight project is not just a commercial venture, but part of a national strategy for zero-emission aviation leadership.

Technological Innovations and Industry Developments

Midnight’s Transition to Production

Archer Aviation achieved a significant milestone with the successful transition flight of the Midnight aircraft in June 2024. This test validated the aircraft’s tilt-propeller design and battery performance, marking a key step toward FAA certification, which is expected by late 2025. The aircraft has already completed over 400 test flights, demonstrating its readiness for scaled production.

The production ramp-up is supported by the opening of Archer’s 400,000 square foot facility in Georgia, where automotive partner Stellantis brings its expertise in high-volume manufacturing. GKN’s role in producing critical airframe components in the UK complements this U.S.-based final assembly, creating a transatlantic supply chain that blends aerospace precision with automotive scalability.

This dual-continent strategy is designed to optimize both cost and efficiency, ensuring that Archer can meet its ambitious delivery targets. It also reflects a growing trend in the AAM sector: the integration of traditional aerospace suppliers with new mobility startups to accelerate commercialization.

Advancements in Composite Manufacturing

GKN’s Bristol facility has developed a proprietary resin transfer molding process specifically for Midnight’s wings. This innovation reduces material waste compared to traditional composite layup methods, contributing to both cost savings and environmental sustainability. The process also enhances structural integrity, which is critical for meeting aviation safety standards.

These advancements build on GKN’s prior work with other AAM initiatives, where it delivered full composite wing assemblies for prototype eVTOLs. The company’s track record in composite technologies spans decades and includes contributions to major aircraft platforms like the Airbus A350 and the F-35 Lightning II.

By applying these technologies to the eVTOL sector, GKN is helping to bridge the gap between experimental aviation and mass-market deployment. The ability to produce high-strength, lightweight components at scale is essential for making eVTOLs commercially viable and environmentally sustainable.

Conclusion

The expanded collaboration between GKN Aerospace and Archer Aviation represents a pivotal moment in the evolution of urban air mobility. By combining GKN’s manufacturing expertise with Archer’s innovative aircraft design, the partnership is setting the stage for large-scale eVTOL production in the UK. This initiative not only supports Archer’s commercial goals but also aligns with the UK’s broader ambitions to lead in sustainable aviation technologies.

As the eVTOL sector matures, success will depend on overcoming regulatory, infrastructural, and production challenges. However, the groundwork laid by this partnership demonstrates a viable path forward. With continued investment, innovation, and collaboration, the vision of zero-emission urban air travel could become a reality within the next decade.

FAQ

What is the goal of the GKN and Archer collaboration?
The goal is to manufacture critical airframe components for Archer’s Midnight eVTOL aircraft, supporting its commercial rollout and advancing sustainable urban air mobility.

Where will the Midnight aircraft be manufactured?
Key components will be produced at GKN Aerospace’s UK facilities, while final assembly will occur at Archer’s facility in Georgia, USA.

What makes the Midnight eVTOL unique?
Midnight features a range, multiple propellers, independent battery packs, and a cruising speed, emphasizing safety and urban efficiency.

How does this partnership support UK industry?
The project is expected to create numerous high-skilled jobs and aligns with the UK government’s Aerospace Sector Deal and sustainability goals.

When is the Midnight expected to be certified?
FAA certification for the Midnight aircraft is anticipated by late 2025, following over 400 successful test flights.

Sources: GKN Aerospace, Archer Aviation, Aerospace Technology Institute, Melrose Industries