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

A New Dawn for Aviation: Air New Zealand and BETA Launch Electric Aircraft Trials

The future of aviation is quietly taking flight in New Zealand. In a significant move towards decarbonizing the skies, Air New Zealand has partnered with U.S. aerospace innovator BETA Technologies to begin trialing an all-electric aircraft. This collaboration, a cornerstone of the airline’s “Next Generation Aircraft programme,” was marked by the inaugural New Zealand flight of the BETA ALIA CX300 from Tauranga Airport on October 17, 2025. The event, which began with a sunrise blessing, signals more than just a test flight; it represents a tangible step in exploring sustainable solutions for regional air travel.

This initiative places New Zealand at the forefront of a global shift in aviation. For years, the concept of electric-powered commercial flight has been a distant goal. Now, through a carefully planned technical demonstrator program, we are seeing the practical application of this technology. The four-month trial is designed to be a rigorous evaluation, providing crucial data on how an electric aircraft performs within New Zealand’s unique geography and weather conditions. It’s a cautious but determined stride into what could become the new standard for connecting communities.

The partnership itself is the result of a meticulous global search by Air New Zealand, which reviewed 30 different manufacturers before selecting BETA Technologies. The goal is clear: to learn, adapt, and pave the way for integrating zero-emission aircraft into its domestic network, initially for cargo and, in the future, for passenger services. This trial is not just about testing a machine; it’s about building an operational blueprint for a cleaner era of aviation.

A Strategic Leap into Sustainable Aviation

Air New Zealand’s commitment to sustainability is not a recent development, but the “Next Generation Aircraft programme” represents its most ambitious effort yet. The program is built on a foundation of proactive research and strategic partnerships aimed at identifying and vetting viable technologies that can reduce the airline’s carbon footprint. The selection of BETA Technologies was a deliberate choice, favoring a company with a pragmatic approach to design and a clear path to commercialization.

The Star of the Show: The BETA ALIA CX300

At the heart of this trial is the BETA ALIA CX300, a battery-electric, conventional take-off and landing (CTOL) aircraft. Its design is a key reason it was chosen. By functioning like a traditional airplane, it can utilize existing airport infrastructure, which dramatically lowers the barrier to adoption. There is no need for specialized runways or vertical take-off pads, allowing for faster and more efficient integration into the current network.

The aircraft boasts zero in-flight emissions and operates with significantly less noise than its conventional counterparts, a major benefit for communities near airports. Configured for this trial with two seats for crew, it offers a cargo capacity of 5.6 cubic meters (200 cubic feet). With a mission range of approximately 398 kilometers (215 nautical miles), it is well-suited for many of New Zealand’s short-haul domestic routes, making it an ideal candidate for connecting regional centers.

The ALIA CX300 is designed for all-weather deployment, a critical feature for operating reliably in New Zealand’s often-variable climate. This focus on practical, real-world application is what sets the aircraft and this trial apart. It’s less about futuristic concepts and more about what can be safely and efficiently implemented in the near future.

“This first flight marks the powerful intersection of pragmatic design and operational innovation. We built the ALIA CX300 on a foundation of simplicity to ensure a fast, safe, and efficient path to commercial service. With this ‘Tech Demonstrator’ collaboration, Air New Zealand is not just validating a single aircraft, they are creating the rigorous operational blueprint that will serve as a model for operators around the world who are serious about unlocking low-cost, sustainable connectivity for their regional communities.” – Chris Caputo, BETA Technologies Director of Flight Operations

The Trial Program: A Blueprint for the Future

The four-month technical demonstrator is more than a simple test; it’s a comprehensive fact-finding mission. The data gathered will be invaluable for Air New Zealand, its partners, and regulators in understanding the capabilities and limitations of current-generation electric aircraft. This knowledge is essential for developing safety protocols, maintenance procedures, and a realistic timeline for commercial deployment.

A Phased Approach to Testing

The trial is structured in distinct phases to systematically assess the ALIA CX300’s performance. After its arrival in early October and the inaugural flight from Tauranga, the aircraft will be based at Hamilton Airport. During this initial phase, it will undergo a series of test flights under various conditions and at different altitudes to establish a baseline for its operational performance in the New Zealand environment.

In December, the program will advance to its next stage. The aircraft will be relocated to Wellington Airport to begin conducting flights across the Cook Strait to Blenheim. This route is a vital domestic link and will provide a real-world test case for the aircraft’s ability to handle a busy and commercially significant route. This phase will be critical in evaluating the aircraft’s efficiency and reliability in day-to-day operations.

This methodical progression from controlled testing to simulated commercial routes allows the team to build confidence and gather comprehensive data at each step. It also offers the New Zealand public a chance to see this groundbreaking technology in action, fostering familiarity and excitement for the future of air travel.

Building the Groundwork: Infrastructure and Training

An electric aircraft is only as effective as the ground infrastructure that supports it. Recognizing this, Air New Zealand has proactively installed 65kW mobile chargers at Hamilton, Wellington, and Blenheim airports. This essential infrastructure, funded by the airline’s Climate and Nature Fund, ensures the ALIA CX300 can be charged efficiently between flights. The use of mobile chargers also provides flexibility as the trial progresses and as future needs evolve.

Beyond the hardware, the human element is paramount. A key objective of the trial is to familiarize pilots, engineers, and ground crews with the new technology. In November, Air New Zealand pilots will begin their training on the ALIA CX300, learning the unique characteristics of flying an electric aircraft. This hands-on experience is crucial for developing the skills and standard operating procedures necessary for a safe and successful transition to electric aviation.

“New Zealand has a proud history of aviation innovation and pushing for progress… It’s incredibly special to partner with a global innovator like BETA to ensure New Zealand is a part of shaping what the future of flight might look like both here and around the world. We know aviation will keep changing, it always has. This is a small, cautious step to learn and be part of that change.” – Baden Smith, Air New Zealand General Manager, Fleet, Networks and Strategy

Concluding Section: Charting a Course for Greener Skies

The collaboration between Air New Zealand and BETA Technologies is a landmark moment in the journey toward sustainable aviation. By bringing the ALIA CX300 to New Zealand for a rigorous trial, the airline is moving beyond ambition and into action. This program is a calculated, methodical effort to understand the real-world performance of electric aircraft, from flight dynamics and battery performance to the necessary ground support and personnel training. It’s a foundational project that will yield critical insights for years to come.

While this four-month trial is just one step, its implications are far-reaching. The operational blueprint developed here could serve as a model for other airlines and regions around the world. It positions New Zealand not just as a participant but as a leader in shaping the future of regional air connectivity. As we watch the ALIA CX300 take to the skies, we are witnessing a cautious but profoundly important step toward a future where air travel is cleaner, quieter, and more sustainable for everyone.

FAQ

Question: What aircraft is Air New Zealand trialing?
Answer: Air New Zealand is trialing the BETA ALIA CX300, an all-electric, conventional take-off and landing (CTOL) aircraft designed for cargo and regional transport.

Question: What is the main purpose of this trial?
Answer: The primary purpose is to conduct a four-month technical demonstrator program to assess the aircraft’s performance in New Zealand’s specific operational conditions and to help Air New Zealand understand the requirements for integrating electric aircraft into its network.

Question: Will this aircraft be used for passenger flights?
Answer: The initial trial is focused on assessing the aircraft for cargo routes. The long-term goal of Air New Zealand’s “Next Generation Aircraft programme” includes exploring the feasibility of electric aircraft for passenger services in the future.

Question: What is the range of the BETA ALIA CX300?
Answer: The aircraft has a mission range of up to approximately 398 kilometers (215 nautical miles), making it suitable for many of New Zealand’s domestic short-haul routes.

Sources

• Air New Zealand Newsroom

Horizon Aircraft’s Selection of Pratt & Whitney Canada’s PT6A Engine, A Strategic Leap in Hybrid eVTOL Innovation

The advanced air mobility (AAM) sector is undergoing a transformative phase, with eVTOL aircraft at the forefront of this evolution. As the industry races to develop practical, safe, and efficient solutions for urban and regional air transport, the choice of propulsion systems has emerged as a critical differentiator. Hybrid-electric architectures, which combine the benefits of conventional engines with electric propulsion, are increasingly being recognized for their operational flexibility and real-world applicability.

In this context, Horizon Aircraft’s decision to select the Pratt & Whitney Canada PT6A engine for its Cavorite X7 hybrid eVTOL marks a pivotal moment for both the company and the wider industry. This partnership brings together two prominent Canadian aerospace leaders and signals a commitment to reliability, efficiency, and innovation in next-generation aircraft design. The move not only enhances Horizon’s technical capabilities but also underscores the growing influence of Canadian firms in the global AAM landscape.

This article explores the significance of Horizon Aircraft’s engine selection, the technical and strategic rationale behind the decision, and its implications for the future of hybrid eVTOLs and the broader air mobility market.

The Cavorite X7 and the Promise of Hybrid eVTOLs

Design Philosophy and Operational Advantages

Horizon Aircraft’s Cavorite X7 is designed to bridge the gap between helicopters and fixed-wing aircraft by leveraging a hybrid propulsion system. Unlike many eVTOLs that rely solely on batteries, the Cavorite X7 integrates a gas-powered PT6A engine with electric motors, enabling vertical takeoff and landing while maintaining the speed and range of a conventional airplane. The aircraft features the patented HOVR Wing technology, with 14 fans embedded in the wings for lift during takeoff and landing. Once airborne, these fans are covered, and the aircraft transitions to forward flight powered by a pusher propeller.

This hybrid approach addresses a key limitation of all-electric eVTOLs, range and infrastructure dependency. By using the PT6A engine as an onboard generator, the Cavorite X7 can recharge its batteries in-flight, drastically reducing downtime and enabling operations in remote or off-grid locations where charging stations are unavailable. This flexibility is particularly valuable for emergency services, disaster relief, and military missions, where operational reliability is paramount.

The Cavorite X7 is engineered to carry a pilot and up to six passengers, targeting a maximum speed of 450 km/hr (280 mph) and a range of approximately 800 kilometers (500 miles). These specifications position the aircraft as a versatile solution for both urban and regional missions, offering the vertical agility of a helicopter with the efficiency and speed of a fixed-wing aircraft.

“The Cavorite X7’s hybrid design enables unprecedented speed, range, efficiency, and dependability that other eVTOLs and helicopters cannot match, while reducing hydrocarbon emissions by up to 30% relative to conventional aircraft conducting similar operations.”, Horizon Aircraft

Technical Rationale for Selecting the PT6A Engine

The PT6A engine, produced by Pratt & Whitney Canada, is widely recognized as one of the most reliable and efficient turboprop engines in aviation history. Since its introduction in the 1960s, over 50,000 PT6A engines have been manufactured, collectively amassing hundreds of millions of flight hours. This track record of reliability and performance made the PT6A a natural choice for Horizon Aircraft’s ambitious hybrid eVTOL project.

The PT6A’s modular reverse flow architecture simplifies installation and maintenance, which is especially beneficial for new aircraft platforms like the Cavorite X7. Its power-to-weight ratio and operational flexibility are well-suited to the demands of hybrid-electric propulsion, where the engine must serve as both a primary power source and a generator for the battery system. The use of a proven, certified engine also mitigates risks associated with developing entirely new propulsion systems, streamlining the path toward regulatory approval and commercial deployment.

In the Cavorite X7, the PT6A will not only provide thrust but also generate electricity for the aircraft’s electric motors and recharge the battery system during flight. This hybrid configuration extends the aircraft’s range and endurance beyond what is feasible with current battery technology alone, while also reducing reliance on ground-based charging infrastructure.

“For more than six decades, the PT6 engine has been at the heart of countless innovations in aviation, continually evolving to meet the needs of customers worldwide.”, Scott McElvaine, Vice President, Sales & Marketing and Business Development, Pratt & Whitney Canada

Market Context and Strategic Implications

The global eVTOL market is rapidly expanding, with projections estimating a value of USD 28.6 billion by 2030. While many competitors, such as Joby Aviation and Archer Aviation, have focused on all-electric designs, the hybrid-electric segment is gaining traction for applications that require longer flight times, greater payloads, and operations in less developed regions. Horizon Aircraft’s strategic bet on hybrid technology positions it to capture a distinct segment of the market that prioritizes operational flexibility and real-world applicability.

The formal purchase agreement between Horizon Aircraft and Pratt & Whitney Canada underscores the strength of the Canadian aerospace sector. By collaborating domestically, both companies are contributing to Canada’s reputation as a hub for advanced air mobility innovation. This partnership is not only a technical milestone but also a statement of intent regarding the future direction of the industry.

As the AAM sector moves toward commercialization, the ability to offer certified, reliable, and efficient aircraft will be a key differentiator. The selection of the PT6A engine is a critical step in Horizon Aircraft’s journey toward type certification and eventual production, providing a solid foundation for further development and market entry.

Challenges, Opportunities, and the Road Ahead

Addressing Technical and Regulatory Hurdles

Developing a new category of aircraft like the hybrid eVTOL comes with significant technical and regulatory challenges. Integrating a hybrid propulsion system requires careful management of weight, thermal loads, and system redundancies to ensure safety and reliability. The complexity of certifying a novel aircraft design, especially one that combines established and emerging technologies, adds another layer of difficulty.

However, the use of the PT6A engine, with its established certification and operational history, helps mitigate some of these risks. By leveraging a proven powerplant, Horizon Aircraft can focus its resources on refining the hybrid architecture and flight systems, rather than developing an entirely new engine from scratch. This approach may also facilitate a smoother certification process with regulatory authorities.

Regulatory agencies worldwide are still developing frameworks for certifying eVTOL and hybrid aircraft. Companies that can demonstrate compliance with existing standards, while also contributing to the evolution of new regulatory pathways, are likely to gain a competitive advantage as the market matures.

“Hybrid aircraft offer operational advantages over all-electric designs, including using warm air from the engine for de-icing and cabin heating. The aircraft’s battery array can recharge en route within minutes, allowing for a full charge during the landing phase.”, Brandon Robinson, CEO, Horizon Aircraft

Environmental Impact and Sustainability Considerations

One of the primary drivers behind the adoption of hybrid and electric propulsion in aviation is the potential for reduced environmental impact. Horizon Aircraft projects that the Cavorite X7 will reduce hydrocarbon emissions by up to 30% compared to conventional aircraft on similar missions. This reduction is achieved through a combination of efficient engine operation, optimized flight profiles, and the ability to operate electrically during certain phases of flight.

While hybrid systems do not eliminate emissions entirely, they represent a pragmatic step toward decarbonizing regional and urban air mobility. In scenarios where ground-based charging infrastructure is limited or unreliable, hybrid aircraft can offer immediate operational benefits while still contributing to overall emissions reduction goals.

Looking ahead, further advancements in battery technology and alternative fuels could enable even greater sustainability. The modular nature of the Cavorite X7’s design may allow for future upgrades, such as integration with hydrogen fuel cells or next-generation batteries, as these technologies mature and become commercially viable.

Future Developments and Market Outlook

Horizon Aircraft has been making measurable progress in the development of the Cavorite X7, including wind tunnel testing of a half-scale prototype. The company aims to have a full-scale technology demonstrator flying in the near future, with a target of achieving type certification before 2030. The selection of the PT6A engine is a foundational milestone in this timeline, solidifying a key component of the aircraft’s design and supply chain.

The broader AAM market is characterized by a diversity of approaches to propulsion, ranging from all-electric to hybrid and, potentially, hydrogen-based systems in the future. Horizon Aircraft’s focus on hybrid technology positions it to address a wide range of use cases, particularly those that require extended range and operational flexibility.

As commercialization approaches, the ability to demonstrate reliable, safe, and efficient operations will be a crucial for gaining regulatory approval and market acceptance. Horizon Aircraft’s partnership with Pratt & Whitney Canada provides a strong foundation for meeting these challenges and capturing a share of the rapidly growing eVTOL market.

Conclusion: Implications and the Path Forward

Horizon Aircraft’s selection of the Pratt & Whitney Canada PT6A engine for its Cavorite X7 hybrid eVTOL represents a significant advance in the evolution of advanced air mobility. By leveraging a proven engine with a legacy of reliability and efficiency, Horizon is positioning itself to address real-world operational needs while navigating the complexities of aircraft certification and commercialization.

As the industry continues to evolve, the success of hybrid eVTOLs like the Cavorite X7 will depend on ongoing innovation, regulatory collaboration, and the ability to deliver tangible benefits in terms of speed, range, and sustainability. The partnership between Horizon Aircraft and Pratt & Whitney Canada exemplifies the kind of strategic collaboration that will shape the future of urban and regional air transport, with implications for industry players, regulators, and passengers alike.

FAQ

What is the Cavorite X7?
The Cavorite X7 is a hybrid electric Vertical Take-Off and Landing (eVTOL) aircraft developed by Horizon Aircraft. It is designed for a range of applications, including emergency services, commercial transport, and disaster relief, and features a unique hybrid propulsion system combining a gas turbine engine and electric motors.

Why did Horizon Aircraft choose the PT6A engine?
Horizon Aircraft selected the Pratt & Whitney Canada PT6A engine due to its proven reliability, efficiency, and power-to-weight ratio. The engine’s established certification and operational history make it an optimal choice for the hybrid-electric architecture of the Cavorite X7.

What are the advantages of hybrid eVTOLs over all-electric designs?
Hybrid eVTOLs offer longer range, faster speeds, and the ability to operate in areas without charging infrastructure. They also provide operational benefits such as in-flight battery recharging and reduced downtime compared to all-electric aircraft.

What is the projected environmental impact of the Cavorite X7?
Horizon Aircraft projects that the Cavorite X7 will reduce hydrocarbon emissions by up to 30% compared to conventional aircraft on similar missions, contributing to the aviation industry’s sustainability goals.

When will the Cavorite X7 be available?
Horizon Aircraft is progressing through prototype testing and aims to achieve type certification for a production aircraft before 2030.

Sources: Horizon Aircraft Press Release