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Collins Aerospace Completes HECATE Project Achieving TRL5 for Hybrid-Electric Aircraft

Collins Aerospace completes HECATE project, validating 800V electrical system for hybrid-electric aircraft with TRL5 certification under Clean Aviation initiative.

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

On March 17, 2026, Collins Aerospace, an RTX business, announced the successful completion of the Hybrid-ElectriC regional Aircraft distribution TEchnologies (HECATE) project. According to the company’s press release, this initiative has officially achieved Technology Readiness Level 5 (TRL5), a critical milestone that proves the viability of its electrical architecture design for future hybrid-electric Commercial-Aircraft under real-world simulated conditions.

The HECATE project is a cornerstone of the European Union’s Clean Aviation Joint Undertaking (CAJU), receiving additional support from UK Research and Innovation. Industry data provided in supplementary research reports notes that CAJU operates with a €4.1 billion budget aimed at reducing the greenhouse gas Emissions of regional aircraft by up to 50 percent compared to 2020 standards. The successful conclusion of HECATE’s Phase 1 testing marks a significant step toward the program’s ultimate goal of introducing zero-emission commercial aircraft into service by 2035.

At AirPro News, we recognize that the transition to hybrid-electric Propulsion requires massive leaps in onboard energy management. The HECATE consortium, led by Collins Aerospace and featuring technical coordination by Safran Electrical & Power, has demonstrated that the European aerospace supply chain can collaboratively meet these high-voltage demands.

The HECATE Project and High-Voltage Aviation

Overcoming Megawatt-Class Challenges

As the Manufacturers industry pivots toward hybrid-electric propulsion, the electrical demands placed on aircraft systems increase exponentially. Traditional electrical networks are ill-equipped to handle megawatt-class power levels without adding prohibitive weight or introducing high-voltage hazards such as arcing and electromagnetic interference. According to the Collins Aerospace press release, the HECATE project directly addressed these hurdles by developing a lightweight, compact, and holistically optimized electrical power generation and distribution system.

During the testing phase, the consortium successfully demonstrated an 800-volt architecture capable of handling more than 500 kilowatts (kW) of power. To achieve this safely and efficiently, the Phase 1 CAJU project utilized digital twin technology. The official release notes that simulating real-world operations digitally significantly reduced physical testing time while ensuring the system adhered to strict electromagnetic compatibility standards.

“Through successful collaboration with HECATE consortium partners, we have advanced critical technologies for hybrid-electric propulsion and more electric aircraft to meet future high power, high-voltage aircraft demands. With efficient, lightweight, and compact electrical power distribution technologies, Collins is well-positioned for continued maturation and integration testing under Clean Aviation Phase 2 programs, moving closer to commercial viability.”

— Kristin Smith, Vice President of Electric Power Systems at Collins Aerospace

Ground Testing at the “Copper Bird” Facility

Simulating Flight in Niort, France

The physical validation of the HECATE system took place at Safran Electrical & Power’s specialized “Copper Bird” facility in Niort, France. According to supplementary project data, the Copper Bird is a unique ground-test platform designed to integrate and test an aircraft’s entire advanced electrical system in a controlled environment before flight testing begins.

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The integration process was a massive collaborative effort. The Clean Aviation Joint Undertaking reports that the project was jointly developed by 38 participating entities across 11 European countries, including major players like Airbus Defence and Space and Leonardo, alongside various universities. Bringing hardware from dozens of partners into a single, functioning 500 kW network on the Copper Bird proved the efficacy of the consortium’s design.

“We are very proud to have integrated the full suite of partner systems from the HECATE consortium into our state-of-the-art electrical systems test bench in Niort. This integration highlights the strength of our collaboration and our technical leadership in hybrid-electric and electric propulsion.”

— Agnès Pronost-Gilles, Executive VP & General Manager for Power Division, Safran Electrical & Power

Transitioning to Clean Aviation Phase 2

OSYRYS and LEIA Initiatives

The completion of HECATE serves as the launchpad for Phase 2 of the Clean Aviation initiative. According to industry research reports, CAJU announced €945 million in funding for 12 new Call 3 projects in late 2025, with work officially kicking off in early 2026. These projects aim to take the technologies proven in HECATE from the laboratory to the sky, with initial flight tests slated for the 2028–2029 timeframe.

The Collins Aerospace release highlights two key Phase 2 projects: OSYRYS and LEIA. OSYRYS, led by Safran Electrical & Power, will focus on developing and testing electrical systems specifically for hybrid-electric regional aircraft. Meanwhile, LEIA, coordinated by Airbus, aims to scale these hybrid-electric architectures for larger, short-to-medium range commercial aircraft.

“Hybrid-electric aircrafts need reliable and powerful electrical architectures to safely fly our skies — and HECATE has brought us a decisive step closer towards this goal with tangible results and win-win collaboration with EASA. At Clean Aviation, we will be excited to see how Phase 2 projects build on HECATE achievements and will further mature the technology for an entry into service by 2035.”

— María Calvo, Head of Unit Project Management at Clean Aviation

AirPro News analysis

The successful TRL5 certification of the HECATE project underscores a critical, often-overlooked element of next-generation aviation: regulatory synergy. By collaborating continuously with the European Union Aviation Safety Agency (EASA) and standards groups like EUROCAE throughout the development process, the HECATE consortium has ensured that these high-voltage systems are not just functional in a lab, but fundamentally certifiable for commercial flight.

Furthermore, while Sustainable Aviation Fuel (SAF) remains the industry’s primary short-term tool for decarbonization, the physical limits of SAF production necessitate mechanical innovations. The 800-volt, 500 kW architecture proven by Collins Aerospace and Safran represents the foundational infrastructure required to make hybrid-electric regional flights a reality by the 2035 target. Without these high-voltage distribution networks, the transition to zero-emission aviation would stall at the propulsion level.

Frequently Asked Questions (FAQ)

  • What is the HECATE project?
    HECATE (Hybrid-ElectriC regional Aircraft distribution TEchnologies) is a European research initiative aimed at developing high-voltage electrical power generation and distribution systems for future hybrid-electric aircraft.
  • What does TRL5 mean?
    Technology Readiness Level 5 (TRL5) indicates that a technology has been rigorously tested and validated in a relevant, simulated environment, in this case, Safran’s “Copper Bird” ground-test platform.
  • When will these hybrid-electric aircraft fly?
    Phase 2 projects (like OSYRYS and LEIA) aim to begin flight tests between 2028 and 2029, with the ultimate goal of commercial entry into service by 2035.

Sources: Collins Aerospace Press Release, HECATE Project Official Site

Photo Credit: RTX

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Electric Aircraft

AIR Surpasses $1 Billion in Orders for Smart eVTOL Aircraft

Israel’s AIR reaches $1 billion in eVTOL orders, reporting $35 million revenue and FAA certification progress for AIR ONE personal aircraft.

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This article is based on an official press release from AIR.

AIR Surpasses $1 Billion in Orders for Smart Aircraft and eVTOLs

Smart aircraft manufacturer AIR has officially surpassed $1 billion in orders, signaling strong market interest in its electric vertical takeoff and landing (eVTOL) vehicles. According to a company press release, the Israel-based firm has accumulated a waitlist of more than 3,300 customers, with many having already placed deposits for future deliveries.

The milestone highlights the growing demand for next-generation air mobility solutions across personal, commercial, and defense sectors. AIR reported over $35 million in booked revenue to date, which the company attributes primarily to the sale and delivery of its Heavy-Lift unmanned aerial systems (UAS), alongside mobile ground control stations, parts, and servicing packages.

As the eVTOL industry moves closer to widespread commercialization, AIR is positioning itself to capitalize on emerging regulatory frameworks. The manufacturer noted that its flagship personal aircraft, the AIR ONE, is currently being considered under the Federal Aviation Administration’s (FAA) Modernization of Special Airworthiness Certificates (MOSAIC) framework as a Light Sport Aircraft (LSA).

Breaking Down the $1 Billion Order Book

The bulk of the company’s billion-dollar backlog stems from its consumer-focused model. In its official announcement, AIR detailed that 3,290 of the orders are for the AIR ONE personal aircraft. This two-seat, fully electric eVTOL is designed for private use and boasts a projected range of 100 miles.

According to the manufacturer’s specifications, the AIR ONE can reach speeds of up to 155 miles per hour and carry a payload of up to 550 pounds. The company stated that these personal aircraft orders will be fulfilled once FAA certification is secured and mass production begins. The aircraft also features redundant safety layers, an airframe parachute system, and “Fly-By-Intent” flight control technology.

Commercial and Heavy-Lift UAS Progress

Beyond personal mobility, AIR is also seeing traction in the commercial and logistics space. The press release indicated that the company has secured more than 25 orders for its AIR Cargo heavy-lift UAS, with two units already delivered to customers.

The cargo variant features a 70-cubic-foot cargo bay and matches the personal model’s 550-pound payload capacity. AIR confirmed it has an active production line for the heavy-lift aircraft and anticipates producing and delivering more than 20 additional units this year.

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Recent Milestones and Strategic Partnerships

The surge in orders follows a series of strategic and financial developments for the eVTOL developer. In July of last year, AIR closed a $23 million Series A funding round led by Entrée Capital, with participation from early backer Dr. Shmuel Harlap.

Furthermore, the company announced in September that its latest U.S.-based prototype had received an FAA Experimental Airworthiness Certification. These regulatory and financial steps are crucial as the company transitions from prototyping to scalable manufacturing, supported by partnerships with the U.S. Air Force’s Agility Prime program, ST Engineering, Nidec Motors, and EDAG.

“Our mission is to make air mobility accessible and routine, while bridging personal, commercial, and defense transportation and operations,” said Rani Plaut, CEO and Co-Founder of AIR, in the press release.

AirPro News analysis

The announcement of $1 billion in orders is a significant indicator of consumer and commercial appetite for eVTOL technology. However, as with many advanced air mobility startups, the transition from pre-orders to delivered, certified aircraft remains the ultimate hurdle. The fact that AIR is already generating real revenue, $35 million booked from its heavy-lift UAS and support systems, sets it apart from competitors that rely entirely on future passenger operations.

By targeting the Light Sport Aircraft category under the FAA’s MOSAIC framework, AIR may find a more streamlined path to market for its personal vehicles compared to the rigorous commercial passenger certification processes faced by air taxi operators. We will continue to monitor their production ramp-up, particularly whether they can meet their goal of delivering more than 20 cargo units this year.

Frequently Asked Questions

What is the AIR ONE?

The AIR ONE is a two-seater, fully electric eVTOL designed for personal use. According to the manufacturer, it features a 100-mile range, speeds up to 155 mph, and a 550-pound payload capacity.

How much revenue has AIR generated?

The company reported over $35 million in book revenue, driven largely by its Heavy-Lift UAS deliveries, mobile ground control stations, parts, and servicing packages.

Has the FAA certified AIR’s aircraft?

In September, AIR’s U.S.-based eVTOL prototype received an FAA Experimental Airworthiness Certification. The AIR ONE is also being considered within the Light Sport Aircraft category under the FAA’s MOSAIC framework.

Sources

Photo Credit: AIR

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Sustainable Aviation

SHEIN Expands Sustainable Aviation Fuel Use with DHL Partnership

SHEIN partners with DHL Express to pilot Sustainable Aviation Fuel in air freight, supporting emissions reduction amid market and regulatory challenges.

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This article is based on an official press release from SHEIN.

On March 24, 2026, global fashion retailer SHEIN announced a new agreement with DHL Express to utilize the logistics provider’s GoGreen Plus service. This initiative integrates Sustainable Aviation Fuel (SAF) into SHEIN’s international air freight operations, marking another step in the company’s efforts to address lifecycle emissions associated with its supply chain.

According to the official press release, the partnership is designed as an early-stage pilot to help the retailer evaluate economic feasibility, certification frameworks, and operational integration. SHEIN explicitly acknowledges that the immediate emissions impact will be modest relative to its total air transport footprint, reflecting broader constraints in the global SAF market where alternative fuels represent only a fraction of conventional jet fuel supply.

We note that this move builds upon SHEIN’s previous SAF pilot programs initiated in 2025, signaling a continued corporate push to support capacity-building activities and demand signaling, particularly within the rapidly evolving Asia-Pacific (APAC) region.

Expanding SAF Pilots and Logistics Partnerships

The DHL GoGreen Plus Agreement

Under the new agreement, SHEIN will leverage DHL’s GoGreen Plus service, which utilizes an “insetting” approach to reduce Scope 3 greenhouse gas emissions. Rather than fueling specific cargo planes directly with SAF, the fuel is introduced into DHL’s broader aviation network. The resulting lifecycle emissions reductions are then allocated to SHEIN using internationally recognized carbon accounting and certification frameworks.

“Signing the GoGreen Plus agreement with SHEIN marks another important milestone in DHL Express’s commitment to driving the green transformation of air logistics. As a long-term partner in SHEIN’s global logistics network, we are pleased to work together to explore how sustainable aviation fuel can be integrated into their air cargo operations.”

— John Pearson, CEO of DHL Express, in a company statement

Building on 2025 Initiatives

The DHL partnership is part of a broader, multi-carrier strategy. Industry research highlights that in 2025, SHEIN procured 187.3 tonnes of SAF across 14 Atlas Air charter flights, achieving an estimated emissions reduction of 579.1 tonnes of CO₂ equivalent (tCO₂e). Furthermore, the company signed a Memorandum of Understanding (MoU) with Lufthansa Cargo in August 2025 to accelerate SAF adoption.

Regionally, SHEIN is also participating in a China-based SAF pilot program organized by China National Aviation Fuel (CNAF) and the Second Research Institute of Civil Aviation of China (CASRI). Through this initiative, the retailer plans to procure an initial batch of SAF from Air China Cargo, utilizing traceability mechanisms to track usage.

“Working with partners such as DHL allows us to better understand how sustainable aviation fuel solutions may be incorporated into air cargo logistics. Initiatives like this are part of SHEIN’s broader efforts to explore how emerging approaches across the aviation sector may contribute to addressing carbon emissions associated with air transport.”

— Mustan Lalani, Head of Sustainability at SHEIN

Global Bottlenecks and the Cost of Decarbonization

Production and Pricing Realities

SHEIN’s press release notes that wider adoption of SAF remains constrained by limited production capacity and higher costs. Data from the International Air Transport Association (IATA) released in December 2025 provides stark context for these limitations. According to IATA, global SAF production reached 1.9 million metric tons in 2025. While this doubled the output of 2024, it still represented only 0.6% of total global jet fuel consumption.

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Growth is projected to slow slightly in 2026, reaching an estimated 2.4 million metric tons, or roughly 0.8% of global demand. Furthermore, SAF currently trades at two to five times the price of conventional fossil jet fuel. IATA estimates that this premium added approximately $3.6 billion to the aviation industry’s fuel costs in 2025 alone.

Policy Friction

The macroeconomic challenges are compounded by regulatory friction. IATA has publicly criticized certain regional mandates, arguing that they have distorted markets and increased compliance costs without guaranteeing adequate fuel supply.

“SAF production growth fell short of expectations as poorly designed mandates stalled momentum in the fledgling SAF industry… If the objective is to increase SAF production to further the decarbonization of aviation, then they [policymakers] need to learn from failure and work with the airline industry to design incentives that will work.”

— Willie Walsh, Director General of IATA (December 2025)

The Asia-Pacific Momentum

Regulatory Shifts and Capacity Building

The press release emphasizes strengthening the demand signal for SAF in the Asia-Pacific region through capacity-building activities. Industry data shows that APAC is currently undergoing a massive shift in SAF infrastructure and regulation, transitioning from voluntary goals to concrete mandates.

Singapore implemented a confirmed goal of 1% SAF by 2026, funded by a passenger levy, while Japan is finalizing a 10% SAF mandate by 2030. South Korea, India, and Indonesia are also rolling out blending roadmaps expected to take effect around 2027.

To support this regulatory push, physical infrastructure is scaling up. Neste operates a significantly expanded SAF refinery in Singapore, and Hong Kong-based EcoCeres is expanding into Malaysia. Additionally, in May 2025, the World Economic Forum (WEF) and GenZero launched “Green Fuel Forward,” an initiative specifically designed to scale SAF demand and build regional capacity for aviation decarbonization in APAC, involving major airlines and logistics firms like DHL.

AirPro News analysis

SHEIN’s latest announcement reflects a maturing corporate approach to aviation decarbonization. By explicitly stating that the emissions impact of these early-stage pilots will be “modest,” the company avoids the pitfalls of greenwashing and aligns its messaging with the stark realities of the global SAF market. The reliance on DHL’s GoGreen Plus “book-and-claim” model highlights that, for global shippers, insetting remains the most viable mechanism to participate in the SAF economy without requiring direct physical access to alternative fuels at every origin airport. As APAC mandates like Singapore’s 2026 target take effect, corporate demand signals from high-volume freight users like SHEIN will be critical in justifying the massive capital expenditures required for regional SAF refineries.

Frequently Asked Questions

What is DHL’s GoGreen Plus service?

GoGreen Plus is a service offered by DHL Express that allows customers to reduce the Scope 3 carbon emissions associated with their freight. It uses an “insetting” or “book-and-claim” model, where DHL purchases Sustainable Aviation Fuel (SAF) and introduces it into its broader aviation network, allocating the certified emissions reductions to the participating customer.

How much of global aviation fuel is currently SAF?

According to December 2025 data from the International Air Transport Association (IATA), SAF accounts for only 0.6% of global jet fuel consumption, constrained by limited production capacity and high costs.

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Why is SAF more expensive than conventional jet fuel?

SAF is currently two to five times more expensive than conventional fossil jet fuel due to the high costs of feedstock collection, complex refining processes, and a lack of scaled production infrastructure globally.


Sources: SHEIN Press Release

Photo Credit: SHEIN

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Technology & Innovation

NASA Relocates Pilatus PC-12 to Armstrong for Flight Research

NASA moves its Pilatus PC-12 from Ohio to California to support Advanced Air Mobility and space communication research.

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NASA has officially relocated its highly versatile Pilatus PC-12 research aircraft from the Glenn Research Center in Cleveland, Ohio, to the Armstrong Flight Research Center in Edwards, California. Announced on March 24, 2026, the strategic move aims to maximize the aircraft’s utility across the agency’s diverse flight research initiatives while maintaining its current scientific objectives.

The aircraft, bearing NASA Tail Number 606, has spent the last four years serving as a critical flying laboratory for Advanced Air Mobility (AAM) infrastructure and space communications. By transitioning operations to Armstrong, NASA intends to leverage the center’s specialized expertise in managing deployed aircraft, ensuring the PC-12 can continue its dedicated missions while expanding its availability for cross-agency projects.

A Proven Track Record in Aviation and Space Tech

Advancing Air Mobility and Laser Communications

Since its acquisition by NASA’s Glenn Research Center in 2022 to replace aging fleet members, the 2008 Pilatus PC-12/47E has been instrumental in testing next-generation aviation infrastructure. According to the NASA release, the aircraft conducted extensive low- and high-altitude missions over Ohio to evaluate commercial communications technologies, including radio, cellular, and satellite systems. These tests are foundational for the safe integration of highly automated transportation systems, such as urban air taxis and cargo drones.

Beyond terrestrial aviation, the PC-12 played a pivotal role in a groundbreaking communications relay experiment with the International Space Station (ISS). NASA reports that the aircraft utilized a portable laser terminal to transmit a 4K video stream through a ground network and satellite directly to the ISS. Notably, this test successfully demonstrated the optical system’s ability to penetrate cloud coverage, overcoming a historical hurdle for laser-based space communications.

The Strategic Shift to Armstrong

Embracing the Deployed Aircraft Concept

The relocation to Edwards, California, which officially took place on February 11, 2026, represents a strategic optimization of NASA’s aviation assets. Armstrong Flight Research Center is renowned for its proficiency in managing “deployed aircraft”, assets that travel globally to execute specific, temporary missions before returning to base.

Darren Cole, Capabilities Manager for the Flight Demonstrations and Capabilities project at NASA Armstrong, highlighted the operational benefits of this transition in the agency’s announcement.

“NASA Armstrong is proficient in supporting a deployed aircraft concept, where our aircraft goes to another part of the country or world to complete a specific mission. That’s exactly what we are going to do with the PC-12, to continue a wide range of flight research.”

— Darren Cole, NASA Armstrong

The cross-country transition was facilitated by NASA Glenn pilots Kurt Blankenship and Jeremy Johnson, and the aircraft was officially welcomed by Troy Asher, Director for Flight Operations at NASA Armstrong. While based in California, the PC-12 will continue to support Glenn’s ongoing research remotely.

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Aircraft Capabilities and Versatility

Why the Pilatus PC-12?

The Pilatus PC-12 is uniquely suited for NASA’s diverse research requirements. The single-engine turboprop features a pressurized cabin, a cruising speed of 322 mph, and the ability to operate at altitudes ranging from 4,000 to 30,000 feet. Furthermore, its capacity to land on short, unpaved runways makes it highly adaptable for remote or challenging deployments.

James “J.D.” Demers, Chief of Flight Operations at NASA Glenn, explained the original rationale for selecting the PC-12 in the agency’s release.

“We needed an aircraft that had the ability to fly at high and low altitudes, was fuel efficient and had the cargo capacity to carry researchers and monitoring equipment… It also needed to take off and land in a variety of challenging airport situations.”

— James “J.D.” Demers, NASA Glenn

AirPro News analysis

We view this relocation as a clear indicator of NASA’s broader push toward resource optimization and inter-center collaboration. By centralizing the PC-12’s flight operations at Armstrong, a facility purpose-built for experimental aviation support, the agency can reduce operational redundancies while keeping the aircraft active for Glenn’s specific technology development needs.

Furthermore, the continued focus on Advanced Air Mobility (AAM) infrastructure testing underscores the urgency of preparing national airspace for autonomous air taxis and drone deliveries. The PC-12’s ongoing work in this sector will likely yield critical data required by the Federal Aviation Administration and industry stakeholders to certify and safely manage the next generation of commercial Aviation.

Frequently Asked Questions

What is the NASA PC-12 used for?

The Pilatus PC-12 serves as a flying laboratory for testing Advanced Air Mobility (AAM) communications and conducting laser relay experiments with the International Space Station.

Why was the aircraft moved to NASA Armstrong?

The move allows NASA to utilize Armstrong’s “deployed aircraft” operational model, maximizing the aircraft’s availability for cross-agency missions while continuing to support its original research goals remotely.

When did the relocation occur?

The aircraft officially arrived at NASA Armstrong on February 11, 2026, and the strategic move was publicly announced by the agency on March 24, 2026.

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NASA

Photo Credit: NASA

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