This article is based on an official press release from Beyond Aero and additional public industry data.

Beyond Aero Advances Industrialization Plans with Factory Feasibility Study

Beyond Aero, the Toulouse-based developer of hydrogen-electric business aircraft, has officially completed the feasibility study for its future manufacturing facility. According to a company announcement, this milestone marks a critical transition from the design and prototyping phase to industrial-scale production. The company is now actively evaluating potential sites in France and across Europe to host the new plant.

The study, conducted in collaboration with industrial partners Porsche Consulting and the Kardham Group, outlines a blueprint for a facility capable of producing up to 120 aircraft annually. This development comes as the company solidifies its financial standing, having closed a $20 million Series A funding round in late 2024 or early 2025, bringing its total capital raised to approximately $44 million.

Blueprint for a Hydrogen-Electric Factory

The newly finalized industrial plan details a 17,000-square-meter (183,000 sq ft) campus designed to house the Final Assembly Line (FAL), a delivery center, a customer showroom, and integrated Research & Development (R&D) facilities. Beyond Aero states that the site is expected to generate approximately 225 production jobs once fully operational.

Production Capacity and Philosophy

According to the specifications released by the company, the factory is designed for an initial output of 60 aircraft per year, with built-in scalability to reach 120 units annually. The manufacturing strategy, developed with Porsche Consulting, emphasizes “light automation.”

Rather than relying on heavy robotics, which can be capital-intensive and rigid, the assembly process will prioritize flexibility and cost-efficiency by utilizing pre-equipped modules from suppliers. The Kardham Group contributed to the architectural design, focusing on sustainability standards for the new campus.

The “One” Business Jet

The facility will be dedicated to producing the “One” (technically referred to as BYA-1), a clean-sheet business jet designed to be the first hydrogen-electric aircraft certified under CS-23 regulations. The aircraft targets the private aviation market with a range of 800 nautical miles (1,500 km) and a capacity of six to eight passengers.

The propulsion system utilizes gaseous hydrogen fuel cells to power two rear-mounted ducted electric fans. A key design feature noted in technical briefings is the integration of hydrogen tanks into a “fattened” fuselage belly, a safety-centric architecture intended to keep high-pressure fuel lines outside the pressurized cabin.

Commercial Momentum

Beyond Aero reports significant commercial interest in the platform. The company holds Letters of Intent (LOIs) for 108 aircraft, representing a potential order book value of approximately $914 million. The targeted entry into service for the “One” is currently set for 2030, with a design freeze expected by 2027.

AirPro News Analysis

The decision to partner with Porsche Consulting for industrial architecture signals a pragmatic approach to aerospace manufacturing. By avoiding the “automation trap,” where startups over-invest in robotics before stabilizing production rates, Beyond Aero appears to be mitigating the capital risks that have plagued other advanced air mobility ventures.

Furthermore, the search for a factory site across Europe suggests the company is leveraging its potential economic impact to secure favorable incentives. While Toulouse remains a logical hub due to its aerospace ecosystem, the willingness to look elsewhere indicates that regional subsidies and support for green technology will play a decisive role in the final location selection.

Market Context and Competition

The aviation industry faces mounting pressure to decarbonize by 2050, sparking a “hydrogen race” among manufacturers. While giants like Airbus focus on larger commercial airliners through the ZeroE program, Beyond Aero is targeting the “smaller, sooner” segment. By focusing on CS-23 certification (aircraft under 19,000 lbs), the company aims to navigate a faster regulatory pathway compared to commercial transport category aircraft.

Competitors in the sustainable regional and business aviation space include VoltAero and Aura Aero, though these companies often pursue hybrid-electric architectures. Other players like Blue Spirit Aero are also exploring hydrogen-electric light aircraft. However, Beyond Aero’s specific focus on a clean-sheet business jet using gaseous hydrogen distinguishes its market position, particularly regarding infrastructure compatibility with existing Fixed Base Operators (FBOs).

Frequently Asked Questions

What is the timeline for the Beyond Aero “One” aircraft?
The company targets a design freeze by 2027 and Entry into Service (EIS) by 2030.

How is the aircraft powered?
It uses a hydrogen-electric powertrain where gaseous hydrogen fuel cells generate electricity to drive two ducted fans.

Who are the key investors in Beyond Aero?
Investors include Giant Ventures, Bpifrance (Deeptech 2030 fund), Initialized Capital, and angel investors such as Nate Blecharczyk (Airbnb) and Arash Ferdowsi (Dropbox).

Where will the new factory be located?
The site has not yet been selected. Beyond Aero is currently evaluating locations in France and other European countries.

Sources

• Beyond Aero Press Release