Bye Aerospace Partners with Composite Approach for eFlyer 2 Production

This article is based on an official press release from Bye Aerospace.

Bye Aerospace Partners with Composite Approach for Production-Conforming eFlyer 2

Bye Aerospace, the Denver-based developer of the all-electric eFlyer family of aircraft, has officially announced a strategic manufacturing partnership with Composite Approach. According to a press release issued on December 2, 2025, the Oregon-based manufacturer has been selected to produce the major composite structures, including the fuselage, wings, and empennage, for the first production-conforming eFlyer 2.

This agreement marks a significant transition for Bye Aerospace as it moves from the research and development phase into industrialization. The components manufactured by Composite Approach will be utilized to assemble the specific aircraft designated for the eFlyer 2’s inaugural flight as a production-conforming prototype. The company has targeted Spring 2026 for this milestone flight.

Moving Toward Certification

The partnership focuses on the “new-design” eFlyer 2, a term the company uses to distinguish the production-conforming airframe from previous proof-of-concept demonstrators. According to the company’s announcement, this airframe represents the design specifications submitted to the Federal Aviation Administration (FAA) for certification.

Rod Zastrow, CEO of Bye Aerospace, described the partnership as a critical step in the company’s roadmap. In the press release, Zastrow emphasized the shift toward physical production of the certified asset.

“This partnership marks a turning point for Bye Aerospace as we move from design to the physical production of our certified aircraft.”

, Rod Zastrow, CEO of Bye Aerospace

Composite Approach, located in Redmond, Oregon, brings decades of experience in advanced composite manufacturing. The firm is tasked with executing a “build-to-print” mandate, producing high-precision carbon fiber parts based on Bye Aerospace’s engineering data. Brian Harris, CEO of Composite Approach, noted in the release that the project involves “pushing the boundaries of composite technology” to meet the rigorous weight and aerodynamic requirements of electric-aviation.

Technical Specifications and Standards

The production-conforming eFlyer 2 is designed to meet the FAA’s Part 23 Amendment 64 certification basis, a performance-based regulation adapted to accommodate novel technologies like electric propulsion. The aircraft features an optimized aerodynamic design intended to maximize the lift-to-drag ratio, a critical factor for extending the range of battery-electric aircraft.

According to technical details released by the company, the aircraft will be powered by the Safran ENGINeUS™ 100 electric motor. This propulsion system, combined with high-density battery packs, is engineered to support a flight endurance of up to three hours. This endurance target is a key differentiator in the electric flight training market, where current certified competitors often offer significantly shorter flight times.

AirPro News Analysis: The Industrialization Phase

The selection of Composite Approach signals that Bye Aerospace is attempting to de-risk its path to market by leveraging an established supply chain partner rather than building internal fabrication capacity from scratch. By outsourcing the major structural components, Bye Aerospace can concentrate its internal resources on systems integration, final assembly, and the complex FAA certification process.

The stakes are high for the Denver-based manufacturer. With a reported order backlog exceeding $700 million, the company faces pressure to deliver a certified product to flight schools eager to reduce operating costs. Traditional training aircraft burn leaded aviation fuel and require frequent engine maintenance; Bye Aerospace claims the eFlyer 2 will operate at one-fifth the cost of these legacy aircraft.

While the Spring 2026 target for the inaugural flight is ambitious, it represents the critical path toward final certification flight testing. If the eFlyer 2 can achieve its projected 3-hour endurance, it would offer a distinct operational advantage over existing certified electric aircraft, such as the Pipistrel Velis Electro, which is generally limited to local traffic patterns.

Frequently Asked Questions

What is the difference between the “new-design” eFlyer 2 and previous versions?
Previous versions were technology demonstrators or “proof-of-concept” aircraft. The “new-design” refers to the production-conforming aircraft, built exactly to the specifications submitted to the FAA for final certification.

When will the production-conforming eFlyer 2 fly?
Bye Aerospace has targeted Spring 2026 for the inaugural flight of this specific airframe.

Who is manufacturing the airframe?
Composite Approach, a manufacturer based in Redmond, Oregon, will build the fuselage, wings, and empennage.

What is the primary market for this aircraft?
The eFlyer 2 is a two-seat aircraft designed primarily for the flight training market, aiming to replace aging gasoline-powered trainers like the Cessna 172.

Sources

• Bye Aerospace Press Release