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Vertical Aerospace Launches Automated Battery Production Line for Valo eVTOL

Vertical Aerospace starts automated battery pilot production to support Valo eVTOL certification and plans expanded manufacturing with new VEC2 facility.

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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.

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“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.

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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.

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Photo Credit: Vertical Aerospace

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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.

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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 COâ‚‚ equivalent (tCOâ‚‚e). 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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