Vertical Aerospace Launches Automated Battery Production Line for Valo eVTOL

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

Vertical Aerospace has announced the operational launch of its automated battery pilot production line at the Vertical Energy Centre (VEC). This marks a significant step toward the certification and commercialization of the company’s electric aviation technology.

According to the company’s press release, the upgraded facility will support the assembly of battery packs for its upcoming Valo certification aircraft. The move aligns with Vertical’s broader strategy to maintain in-house control over core powertrain technologies while preparing for commercial production, which is currently targeted for 2028.

We note that this development highlights the growing emphasis electric vertical takeoff and landing (eVTOL) manufacturers are placing on vertical integration for critical components, particularly high-performance battery systems that dictate flight capabilities and safety standards.

Upgrading the Vertical Energy Centre

The original 15,000-square-foot Vertical Energy Centre, which opened in 2023, has been instrumental in producing battery systems for the company’s piloted flight testing since 2024. The official press release states that these proprietary batteries have already demonstrated peak power outputs of up to 1.4 megawatts during flight tests.

Now, the facility has been upgraded with automated, aerospace-grade manufacturing processes. Vertical Aerospace notes that these enhancements are designed to improve efficiency, consistency, and overall battery performance as the company moves toward regulatory approval.

Supporting the Valo Certification Fleet

The newly operational pilot line will be tasked with building the final battery packs for seven Valo certification aircraft. These aircraft are critical to Vertical’s certification program with the UK Civil Aviation Authority (CAA) and the European Union Aviation Safety Agency (EASA).

Furthermore, the company stated that this pilot line will provide the necessary capacity for the initial phase of commercial production following certification.

“Bringing our automated battery production line online is a defining step in our journey toward certification and commercialisation,” said Stuart Simpson, CEO of Vertical Aerospace, in the press release.

Simpson added in the release that investing early in aerospace-grade battery manufacturing helps the company reduce integration risks and strengthen supply chain control.

Commercial Strategy and Recurring Revenue

While Vertical Aerospace partners with tier-one aerospace suppliers such as Honeywell, Aciturri, and Syensqo for various aspects of aircraft development, the battery system remains a core in-house technology. The press release emphasizes that this proprietary system will power both the fully electric Valo eVTOL and the company’s hybrid-electric aircraft program.

Beyond initial aircraft sales, Vertical anticipates that battery replacements will generate significant recurring revenue. The company expects to supply approximately 20 battery packs per aircraft over its operational lifespan. By 2035, Vertical projects it will have supplied up to 45,000 battery packs across its operational fleet.

Expanding Manufacturing and UK Footprint

The Upcoming VEC2 Facility

To meet anticipated demand, Vertical is already planning further expansion. A new 30,000-square-foot facility, dubbed Vertical Energy Centre 2 (VEC2), is expected to open later this year adjacent to the current site.

According to the company, VEC2 will serve as a powertrain hub and is projected to triple battery production capacity. By 2027, Vertical expects its total investment across both the VEC and VEC2 facilities to reach £6.4 million ($8.5 million).

Job Creation and Future Production Sites

Vertical currently employs approximately 450 people, primarily in the South West of England. As manufacturing scales, the company projects that the number of highly skilled jobs within its manufacturing ecosystem will rise to at least 2,220 by 2035.

The location for Vertical’s full-rate production and battery facilities has not yet been finalized. The press release indicates that locations both within the UK and internationally are under consideration, with a final decision expected later this year.

AirPro News analysis

We view Vertical’s decision to keep battery development and production in-house as a strategic differentiator in the competitive eVTOL market. While relying on established tier-one suppliers for avionics and aerostructures reduces development risk, controlling the battery technology allows Vertical to directly manage the most critical performance variable in electric aviation: energy density and power output.

The projection of 20 battery packs per aircraft over its lifecycle underscores the intensive wear-and-tear eVTOL batteries will endure, highlighting a lucrative aftermarket revenue stream that could stabilize long-term financials for manufacturers that successfully own their battery intellectual property.

Frequently Asked Questions

When does Vertical Aerospace expect to begin commercial production?
According to the company’s press release, the first phase of commercial production following certification is targeted for 2028.

How much power do Vertical’s proprietary batteries generate?
The company reports that its batteries have delivered up to 1.4 megawatts of peak power during flight testing.

What is the Vertical Energy Centre 2 (VEC2)?
VEC2 is a planned 30,000-square-foot powertrain hub expected to open later this year, which Vertical says will triple its battery production capacity.

Sources

• Vertical Aerospace Press Release