Technology & Innovation
Conflux Technology Joins Honeywell Consortium for Hybrid-Electric Aircraft Thermal Management
Conflux Technology partners with Honeywell in TheMa4HERA consortium to develop advanced thermal management for hybrid-electric aircraft, supporting sustainable aviation by 2035.
Conflux Technology Joins Honeywell-Led TheMa4HERA Consortium: Advancing Thermal Management Solutions for Next-Generation Aviation
The aerospace industry’s pursuit of Sustainability in aviation has reached a critical juncture with the integration of advanced thermal management technologies into hybrid-electric aircraft development. Conflux Technology, an Australian additive manufacturing specialist renowned for innovative heat exchanger solutions, has joined the prestigious TheMa4HERA consortium led by Honeywell. This marks a significant advancement in the quest for climate-neutral aviation by 2035. The collaboration represents a convergence of cutting-edge additive manufacturing capabilities with established aerospace expertise, addressing one of the most challenging technical hurdles in next-generation aircraft: managing heat loads projected to increase from current levels of 35–50 kW to potentially 300–1,000 kW in hybrid-electric regional aircraft. The partnership underscores the critical importance of thermal management systems in enabling the aviation industry’s transition toward sustainable propulsion technologies, while highlighting the growing role of innovative manufacturing techniques in solving complex aerospace challenges.
As aviation moves toward electrification and hybrid Propulsion, the need for efficient, lightweight, and scalable thermal management solutions becomes paramount. The TheMa4HERA project, under the Clean Aviation Joint Undertaking, is a cornerstone initiative in Europe’s strategy to decarbonize air travel, reduce greenhouse gas emissions, and maintain industrial competitiveness. Conflux’s expertise in additive Manufacturing and heat exchanger innovation is poised to play a vital role in solving the complex thermal challenges of next-generation aircraft.
The TheMa4HERA Consortium and Clean Aviation Initiative
The Thermal Management for Hybrid Electric Regional Aircraft (TheMa4HERA) project is one of the most ambitious collaborative efforts in European aerospace research, uniting 24 to 28 partners from 10 European countries under Honeywell’s leadership. This initiative operates within the Clean Aviation Joint Undertaking (CAJU), the European Union’s flagship program for transforming aviation toward a sustainable and climate-neutral future. The Clean Aviation program commands a total budget of €4.1 billion, dedicated to developing disruptive aircraft technologies that aim to reduce greenhouse gas Emissions by at least 30% compared to today’s best aircraft models.
The consortium’s formation reflects the aerospace sector’s recognition that thermal management is a critical bottleneck in hybrid-electric aircraft development. Unlike conventional aircraft, which generate relatively modest heat loads of 35–50 kW, future hybrid-electric regional aircraft must manage heat dissipation in the 300–1,000 kW range due to the integration of batteries, fuel cells, and power electronics. This represents a twenty-fold increase in thermal management requirements, necessitating revolutionary approaches to heat dissipation and system integration. TheMa4HERA aims to demonstrate solutions for this additional heat load while maintaining the lightweight and efficient characteristics essential for aircraft performance.
Honeywell’s leadership leverages decades of experience in thermal management design and manufacturing. The project is coordinated from Honeywell’s international development center in Brno, Czech Republic, the company’s largest R&D facility in Europe. Jan Ludvik, Engineering Director for Honeywell Technology Solutions in the Czech Republic, has highlighted the center’s extensive experience in international collaboration, including Clean Aviation and SESAR. The project’s technical scope covers research on thermal management architecture, air supply systems, air conditioning, system cooling, and comprehensive testing and demonstration activities. Partners like Collins Aerospace contribute specialized expertise in cabin air distribution, ensuring a holistic approach to aircraft thermal management from component optimization to system-level integration.
“Brno is Honeywell’s largest R&D center in Europe, and our dedicated team has extensive experience working with international partners from industry and academia.” — Jan Ludvik, Engineering Director, Honeywell Technology Solutions, Czech Republic
Conflux Technology’s Revolutionary Additive Manufacturing Approach
Conflux Technology’s entry into TheMa4HERA brings a transformative approach to heat exchanger design and manufacturing. Founded by Michael Fuller, who brings 15 years of motorsport engineering experience, Conflux has developed proprietary additive manufacturing techniques that enable the creation of heat exchangers with unprecedented performance characteristics. Their approach departs from traditional manufacturing by using advanced 3D printing to create complex internal geometries, impossible to achieve with conventional methods.
The core innovation lies in creating heat exchangers with significantly enhanced surface area density while maintaining optimal fluid flow and lightweight construction. According to company data, Conflux’s heat exchangers can demonstrate up to 300% higher heat rejection capability compared to conventional designs, with a 22% weight reduction. These improvements are achieved through the integration of intricate internal structures and optimized flow pathways, only feasible with additive manufacturing. As Michael Fuller notes, “We can introduce features that enhance heat transfer without inducing large pressure drops,” enabling higher heat transfer rates without compromising fluid flow.
Conflux’s manufacturing process utilizes EOS M 290 systems with EOS Aluminum AlSi10Mg material, selected after rigorous technical evaluation for their ability to meet ambitious performance targets. The company’s rapid development process allows for concept-to-product progression in just six months, with multiple prototypes built and tested thanks to the elimination of tooling requirements. Beyond design, Conflux employs proprietary post-processing methods to ensure component cleanliness and reliability, critical for aerospace and electric vehicle applications. Advanced verification, including high-resolution CT scanning at Australia’s synchrotron facility, ensures robust and repeatable manufacturing outcomes.
For TheMa4HERA, Conflux will develop lightweight, additive-manufactured heat exchangers for next-generation aircraft, contributing to both Air Cycle Systems (ACS) and Vapour Cycle Systems (VCS). Their involvement includes air-to-air heat exchangers for ACS and air-to-liquid exchangers for VCS evaporator and condenser applications. Fuller emphasizes, “Joining TheMa4HERA aligns with Conflux Technology’s commitment to delivering high-performance thermal solutions that enable energy-efficient, low-emission aviation.”
“Our additive manufacturing capabilities will help the consortium push the boundaries of thermal management design to meet the demands of hybrid-electric propulsion systems.” — Michael Fuller, CEO, Conflux Technology
Technical Challenges and Innovative Solutions in Hybrid-Electric Aviation
The shift to hybrid-electric propulsion in aviation presents unprecedented technical challenges. Traditional aircraft thermal management systems were designed for the predictable heat generation of turbofan engines and avionics. In contrast, integrating electric motors, batteries, fuel cells, and power electronics creates a thermal environment with variable heat loads and strict temperature requirements for optimal component performance and safety.
The scale of the challenge is stark: while current regional aircraft manage 35–50 kW of heat, hybrid-electric models must handle 300–1,000 kW. This increase is due to high-power electric motors, battery packs requiring precise temperature control, fuel cells generating substantial waste heat, and power electronics producing heat during energy conversion. Each subsystem has distinct thermal requirements, with batteries especially sensitive to overheating and cold, and fuel cells requiring stable temperatures for optimal electrochemical reactions.
Conflux’s additive manufacturing enables adaptive thermal management solutions, such as heat exchangers with geometry changes along the flow path to accommodate shifting fluid properties and temperature conditions. For example, in hydrogen fuel cell applications, internal geometry can be tailored to intensify heat transfer as air cools, a feat not possible with traditional manufacturing. TheMa4HERA will leverage comprehensive digital twin capabilities to simulate and optimize component-level requirements for any aircraft architecture, validated in full-scale test facilities at Fraunhofer IBP.
“TheMa4HERA aims to deliver scalable thermal technologies for hybrid-electric aircraft, supporting climate-neutral aviation by 2035.” — TheMa4HERA project statement
Market Context and Industry Growth Projections
The aerospace thermal management system market is a rapidly growing segment, driven by technological complexity and the demand for sustainable aviation. The global market was valued at approximately $3.2 billion in 2023 and is projected to reach $5.8 billion by 2032, with a compound annual growth rate of 6.5%. The hybrid-electric aircraft segment is even more dynamic, with a global market value of $2.80 billion in 2023 and projected growth to $465.60 billion by 2050, reflecting a compound annual growth rate of 21.7%.
North-America currently leads the hybrid-electric aircraft market, accounting for over 37% of the share in 2023, largely due to early adoption and regulatory support in the United States. Europe is expected to see substantial growth, bolstered by initiatives like Clean Aviation and the presence of key aerospace players. The broader electric aircraft market is also expanding, projected to grow from $8.8 billion in 2023 to $40.5 billion by 2033. Companies such as Electra.aero have already secured significant pre-orders for hybrid-electric aircraft designed for short takeoff and landing.
Regulatory pressures and industry commitments to net-zero emissions by 2050 are accelerating demand for advanced thermal management. Regional variations exist: Asia Pacific is poised for growth due to rising air travel and economic expansion, especially in China and India. The presence of established aerospace manufacturers and strong investment in North America underpins continued market leadership, while Europe’s public and private sector support for clean aviation ensures competitive positioning.
Funding Structure and Economic Impact
TheMa4HERA operates within the context of substantial EU investment in clean aviation, with the Clean Aviation Joint Undertaking’s €4.1 billion budget supporting disruptive aircraft technologies. TheMa4HERA itself is funded at €33.7 million, with €25.5 million from the EU and the remainder from private co-investment. The project involves 20 participants across Europe, with public funding covering approximately 75% of costs. The timeline runs from 2023 to 2026, with Technology Readiness Level (TRL) 5 targeted for several system components by 2025–2026.
The economic impact extends beyond R&D, strengthening Europe’s aerospace industrial base and fostering cross-border innovation. Clean Aviation’s second call for proposals allocated €380 million across eight projects, including €33 million specifically for hybrid-electric regional aircraft. This focus on near-term commercial applications aligns with the industry’s goal of achieving net-zero emissions and positions European companies to capture emerging market opportunities.
The project’s funding also supports critical testing infrastructure, such as full-scale demonstration facilities at Fraunhofer IBP, which will benefit the broader aerospace sector. The commercial deployment of resulting technologies is anticipated by 2035, providing a clear pathway from research to market and supporting long-term business planning in the sustainable aviation sector.
Future Implications and Technology Roadmap
TheMa4HERA’s success will be a pivotal enabler for sustainable aviation, with advanced thermal management systems targeted for TRL 5 by 2026 and subsequent flight testing and integration during Clean Aviation Phase 2. The solutions developed will be scalable to larger aircraft and adaptable to various electric and hybrid-electric propulsion architectures, supporting the industry’s climate-neutral ambitions for 2035 and beyond.
The integration of additive manufacturing into aerospace thermal management could transform manufacturing approaches across the industry. Conflux’s demonstration of 300% improved heat rejection and 22% weight reduction highlights the potential for broader adoption of these techniques. The project’s digital twin methodology and collaborative model set new standards for system optimization and cross-border innovation, providing a template for future aerospace research initiatives.
Conclusion
Conflux Technology’s participation in the Honeywell-led TheMa4HERA consortium marks a pivotal moment in sustainable aviation. The project’s goal of managing heat loads up to twenty times greater than current aircraft requires revolutionary thermal management approaches, making the collaboration between Conflux and Honeywell essential for achieving breakthrough performance.
With a €33.7 million investment, including €25.5 million in EU funding, TheMa4HERA exemplifies the strategic importance of thermal management in the transition to hybrid-electric propulsion. The technical innovations emerging from this collaboration, including additive-manufactured heat exchangers and digital twin-based system optimization, will have broad implications for aerospace manufacturing and sustainability. As the industry advances toward net-zero emissions by 2050, the solutions and collaborative models demonstrated by TheMa4HERA will be foundational to the deployment of next-generation aircraft.
FAQ
What is the TheMa4HERA consortium?
TheMa4HERA is a European aerospace research consortium led by Honeywell, focused on developing advanced thermal management solutions for hybrid-electric regional aircraft as part of the Clean Aviation Joint Undertaking.
What role does Conflux Technology play in the consortium?
Conflux Technology contributes its expertise in additive manufacturing and heat exchanger innovation, developing lightweight, high-performance heat exchangers for next-generation aircraft thermal management systems.
Why is thermal management important for hybrid-electric aircraft?
Hybrid-electric aircraft generate much higher heat loads due to batteries, fuel cells, and power electronics. Efficient thermal management is crucial for safety, performance, and enabling the transition to low-emission aviation.
What is the timeline for TheMa4HERA’s technology deployment?
TheMa4HERA aims for Technology Readiness Level 5 by 2026, with commercial deployment of resulting technologies anticipated by 2035.
How is the project funded?
TheMa4HERA is funded at €33.7 million, with approximately 75% from the EU and the rest from private co-investment, as part of the Clean Aviation Joint Undertaking’s €4.1 billion program.
Sources: Conflux Technology
Photo Credit: Conflux Technology
Technology & Innovation
Japan Airlines Deploys Electric Aircraft Washing Robot at Narita
JAL will deploy the Aerowash AW3 robot at Tokyo Narita in 2026, cutting wash times 40% and water use 50%.
Japan Airlines (JAL) will deploy a fully electric, remote-controlled aircraft washing robot at Tokyo Narita International Airport (NRT) later in 2026, a move projected to cut aircraft cleaning times by up to 40 percent and water consumption by half.
In a press release issued on August 28, 2026, the JAL Group announced the introduction of the Aerowash Remote-Controlled Aircraft Washing Robot (AW3), manufactured by Swedish firm Aerowash AB. The deployment marks the first time a domestic airline in Japan has implemented a program-controlled collaborative robot for aircraft exterior cleaning. The initiative aims to improve occupational health and safety for ground staff while reducing the environmental footprint of ground handling operations.
Operational efficiency and environmental impact
The AW3 is fully electric and battery-powered, eliminating direct exhaust emissions on the ramp during operation. According to the JAL Group, the automated system can reduce the time required to wash an aircraft by up to 40 percent compared to traditional manual methods. The robot is also expected to decrease water usage per aircraft by up to 50 percent.
Aviation Week reported that the AW3 system is compatible with several aircraft types in the Japan Airlines fleet, including the Boeing 737, Boeing 767, Boeing 787, and Airbus A350. Full-scale implementation at Narita is scheduled for late 2026 following comprehensive operational training for ground handling staff.
Labor strategy and Automation history
The aviation industry is increasingly turning to automated ground support equipment to mitigate labor shortages and improve turnaround times. Atsuki Kino of the Japan Airlines Airport Ground Handling Planning Department told The Straits Times that the primary objective is workload reduction rather than workforce elimination.
“The goal is not to reduce staff, but to reduce their workloads so they can use the time saved to perform other high-value tasks, changing the way they work,” Kino said.
The AW3 mitigates physical strain and chemical exposure for ground crews who previously conducted exterior washing manually. This is not the airline’s first attempt at automating exterior cleaning. According to Aviation Week, Japan Airlines tested a wired remote-controlled washing system in the 1990s. That initiative was ultimately abandoned due to technical limitations of the era, making the AW3 deployment a successful return to a concept first explored approximately 30 years ago.
AirPro News analysis
The introduction of the Aerowash AW3 by Japan Airlines highlights a broader industry shift toward electrifying and automating ground support equipment. As airlines face persistent global shortages in ground handling personnel, technologies that reduce physical fatigue and chemical exposure become critical retention tools. We expect to see similar collaborative robotics adopted across major Asian and European hubs over the next five years, particularly as Sustainability mandates force operators to scrutinize water consumption and ramp emissions. The 30-year gap between JAL’s initial wired prototype and the AW3 underscores how recent advancements in battery density and spatial programming were required to make automated aircraft washing commercially viable.
Sources: JAL Group
Photo Credit: JAL Group
Sustainable Aviation
KBR PureSAF Technology Selected for Kazakhstan First SAF Plant
KBR licenses PureSAF technology for Kazakhstan’s first SAF facility, using an alcohol-to-jet process with domestic feedstocks.
Global engineering firm KBR announced on August 24, 2026, that it secured a contracts to license its proprietary PureSAF technology and provide engineering design for Kazakhstan’s inaugural Sustainable Aviation Fuel (SAF) production facility. The project, developed in partnership with KazMunayGas-Aero LLP (KMG-Aero) and KazFoodProducts (KFP), will utilize domestic agricultural feedstocks to produce low-carbon aviation fuel via an alcohol-to-jet (AtJ) process.
In a press release detailing the contract award, KBR confirmed the agreement supports Kazakhstan’s strategic objective to establish itself as an international aviation hub while advancing aviation decarbonization. The planned facility will leverage technology developed in collaboration with Swedish Biofuels AB to convert ethanol into drop-in aviation fuel.
Technology and Project Scope
The facility will utilize KBR’s PureSAF technology, an alcohol-to-jet pathway designed to process agricultural feedstocks into sustainable aviation fuel. The foundational trilateral agreement covering the Process Design Package (PDP) and technology licensing was signed by KBR, KMG-Aero, and KFP in Astana on July 23, 2026. KBR, which employs approximately 37,000 people and operates in 28 countries, will provide the engineering framework required to scale the AtJ process for commercial output.
KBR Sustainable Technology Solutions President Jay Ibrahim stated the company is honored to support the national commitment to reduce greenhouse gas emissions.
“KBR’s PureSAF is a feed-flexible, bankable technology that is designed to deliver high SAF yields and supports the project across the full lifecycle. We look forward to closely collaborating and supporting the successful execution of this landmark SAF project,” Ibrahim said.
Kazakhstan’s Aviation Decarbonization Strategy
The KBR contract follows a series of government initiatives aimed at building a domestic SAF supply chain. On August 4, 2026, Kazakh Prime Minister Olzhas Bektenov and Dr. Peter Lee of Hong Kong-based Full Vision Capital signed a memorandum of understanding to explore creating a green aviation fuel ecosystem in the city of Alatau. This proposed ecosystem would cover the full production cycle, from cultivating agricultural feedstock to manufacturing the finished product.
These infrastructure investments align with recommendations from global aviation regulators and industry groups. In April 2026, the International Air Transport Association (IATA) emphasized that continued investment in SAF, alongside new airport infrastructure, is critical for Kazakhstan to capitalize on global passenger and cargo traffic and strengthen its domestic aviation sector.
AirPro News analysis
The KBR contract award represents a concrete technical step in Kazakhstan’s ambition to localize SAF production, but several commercial variables remain undefined. The August 24 announcement did not disclose the financial value of the engineering contract, the projected production capacity of the facility, or a target completion date. We note that while the alcohol-to-jet pathway is a proven method for SAF production, scaling agricultural feedstock supply-chain domestically will be critical to the plant’s long-term viability. The parallel involvement of Full Vision Capital suggests the government is actively working to finance and structure this agricultural supply chain in the Alatau region to ensure the KBR-designed facility has the necessary inputs to operate at scale.
Sources: KBR
Photo Credit: Montage
Technology & Innovation
Boeing and GM Complete Sale of HRL Laboratories to IBM
Boeing and GM finalized the sale of HRL Laboratories to IBM on August 25, 2026, supporting Boeing’s refocus on core aerospace operations.
The Boeing Company and General Motors Company have finalized the sale of their jointly owned research facility, HRL Laboratories, to International Business Machines Corporation (IBM), a divestment that allows the aerospace and automotive manufacturers to redirect resources toward their primary industrial operations.
The transaction transfers ownership of the Malibu, California-based research center, which Boeing and GM previously held in a 50/50 joint venture. The companies initially announced the acquisition agreement on July 23, 2026. Boeing and GM confirmed the completion of the sale in a press release on August 25, 2026, followed by IBM’s official confirmation on August 26. Financial terms of the Acquisitions were not disclosed.
Strategic realignment for Boeing and GM
For Boeing, the sale of HRL Laboratories aligns with a broader corporate Strategy to streamline operations and concentrate capital on its core commercial airplanes, defense, and space divisions. HRL Laboratories was founded in 1948 and has historically provided advanced physical science and engineering research for its parent companies.
In a joint statement, Boeing and GM indicated that they will maintain a working relationship with the laboratory under its new ownership to support their respective technological needs.
“Since its founding in 1948, HRL Laboratories has been a leader in pioneering work in physical science and engineering, and we look forward to IBM building on this legacy. While Boeing and GM will continue to partner with IBM and HRL on quantum applications and advanced technology development, our companies will focus our resources on our respective core businesses and delivering the programs and services necessary to meet our customers’ evolving needs.”
IBM accelerates quantum hardware roadmap
The acquisition provides IBM with HRL’s expertise in silicon-spin qubits, quantum sensing, and advanced materials. IBM plans to integrate these technologies into its dual-track hardware strategy, combining its existing superconducting circuits with HRL’s silicon quantum dot research.
This integration supports the development of the IBM Quantum Starling, a fault-tolerant quantum computer projected to perform 100 million quantum operations by 2029.
Jay Gambetta, Director of Research and IBM Fellow, noted in a company statement that the HRL team brings a broad portfolio of technologies that will strengthen IBM’s long-term plans to deliver useful quantum computing. Gambetta stated the acquisition brings together advances across quantum computing, sensing, and networking.
Rob Vasquez, President and Chief Executive Officer of HRL Laboratories, described the acquisition as the natural next chapter for the facility, noting the team’s dedication to exploring how future quantum computers could be built at unprecedented scales.
AirPro News analysis
We view Boeing’s divestment of HRL Laboratories as a pragmatic step in its ongoing effort to stabilize and refocus its core aerospace Manufacturing businesses. While quantum computing and advanced materials research hold long-term promise for aerospace applications, maintaining a 50 percent stake in a dedicated research laboratory requires capital and management bandwidth that Boeing currently needs for its Commercial-Aircraft production and certification programs. By transitioning from an owner to a partner, Boeing retains access to HRL’s quantum advancements without the financial overhead of managing the joint venture.
Sources: The Boeing Company
Photo Credit: HRL Laboratories
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