The Army on Thursday awarded a $1.9 million Small Business Innovation Research (SBIR) contract to Electra.aero, the manufacturer of a nine-passenger, hybrid-electric short takeoff and landing (eSTOL) design, to perform powered wind tunnel testing.

Similar to Electra’s other SBIR and Small Business Technology Transfer (SBTT) Phase II and III engagements with AFWERX, the innovation arm of the U.S. Air Force, the Army contract is a quid-pro-quo arrangement.

Electra will get the opportunity to leverage military test facilities as it collects data that will inform aircraft design and development. The Army, meanwhile, can explore the eSTOL’s unique capabilities—such as its miniscule runway requirement—for logistics operations in “contested” environments.

“There is a substantial benefit to employing the right-sized aircraft for a given payload-range mission,” said Ben Marchionna, director of technology and innovation at Electra. “Many of the most commonly deployed military logistics solutions in use today are flown well below their intended payload capacity. Our eSTOL aircraft can fulfill these missions while using dramatically less fuel, providing much more range, operating at significantly reduced noise levels, and utilizing the same constrained operational ground footprints.”

According to Electra, the eSTOL cruises at 175 knots and is capable of carrying up to nine passengers or 2,500 pounds of cargo. The company claims it will have more than twice the payload, 10 times the range, and 70 percent lower operating costs compared to electric vertical takeoff and landing (eVTOL) alternatives, while offering lower noise and fuel consumption.

The aircraft has a range of 500 nm for commercial use cases. But with range extensions, the Army will be able to fly it for 1,000 nm.

The defining feature of Electra’s design is its use of blown-lift technology, which redirects slipstream flows over the aircraft’s wings into large flaps and ailerons. By “multiplying lift,” as Electra puts it, the eSTOL can take off at just 35 mph, reducing the runway requirement to 150 feet.

Electra says it is the first manufacturer to deploy blown lift in an aircraft with a distributed electric propulsion system. That system takes the form of eight electric motors powered by a turbogenerator. The latter can run on both electricity or traditional aviation fuel and recharges the aircraft’s batteries in flight. Because of this, airports will not need to install electric aircraft chargers to accommodate it, Electra says.

The manufacturer intends to certify its flagship model as a fixed wing aircraft under FAR Part 23 and EASA CS-23, allowing it to be operated with a standard fixed wing pilot’s certificate. That removes a key hurdle facing the eVTOL industry, which will need to train a new generation of powered-lift-certified pilots under FAA proposals.

The Army will be one of the earliest users of the eSTOL, but Electra has plenty of commercial arrangements lined up. Those include more than 2,000 preorder sales of its flagship aircraft to major customers, among them American operators Bristow Group and JSX and India’s JetSetGo

This week, the manufacturer announced a partnership with Wilbur Air, the newly formed operator subsidiary of Australian vertiport developer Skyportz. Electra and Skyportz in 2021 signed a letter of intent for 100 aircraft.

Electra expects to begin eSTOL deliveries in 2028 following certification.

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Lockheed Martin-backed Electra.aero on Tuesday announced that it topped 2,000 preorder sales for its flagship eSTOL design, an order book the manufacturer values at over $8 billion once fully realized. The nine-seat aircraft is unique, even among electric designs, because of its ability to take off or land with just 150 feet of runway.

Electra reached the milestone after wrapping up three sizable agreements. In December, Finnish on-demand flying platform Lygg agreed to buy up to 300 eSTOLs in a deal valued at over $1 billion. Lygg operators, which mainly serve airports outside Nordic and European metropolises, will be able to purchase the aircraft through a hybrid-as-a-service model, which offers financing.

“Electra’s eSTOL capability allows us to rewrite the definition of direct connections for environmentally conscious business travelers using existing airfields closer to city centers, reducing valuable time spent in the air,” said Roope Kekäläinen, CEO of Lygg.

The company’s order book expanded again last week, when Indian private charter marketplace JetSetGo placed firm orders for 50 aircraft apiece from Electra, Overair, and Horizon Aircraft. Electra will work with the firm, which operates India’s largest on-demand fleet, to identify new routes that can leverage the eSTOL’s unique capabilities.

“India’s geography and demographics make it an ideal launch market for advanced air mobility (AAM),” said Kanika Tekriwal, co-founder and CEO of JetSetGo. “We want to lead the transformation of urban and regional connectivity and believe Electra is the right partner with the technology to make this vision a reality.”

The third agreement, with New York City-based helicopter tour operator Charm Aviation, had not been previously announced. Electra did not disclose the number of aircraft included in Charm’s order, but it said the operator will introduce the eSTOL to heliports and vertiports in bustling Manhattan.

“Electra’s aircraft has the range to transform New York City’s heliports from urban flight terminals into regional transport hubs with direct flights to cities and smaller communities along the East Coast,” said Marc Ausman, chief product officer of Electra.

The Aircraft

Electra says its eSTOL represents the first use of blown lift technology using distributed electric propulsion. Blown lift—which redirects slipstream flows over the aircraft’s wings into large flaps and ailerons—is what allows the design to take off from sites smaller than a soccer field.

Flaps and ailerons redirect the airflows downward to provide lift that would normally be achieved through high-speed takeoff. This, Electra says, allows the eSTOL to get airborne at “neighborhood driving speeds,” shortening the runway requirement and opening up operations out of remote or underutilized airfields.

The aircraft has a range of about 434 nm and a cruise speed of 175 knots, capable of carrying nine passengers or up to 2,500 pounds of cargo. Compared to vertical takeoff designs, it offers more than twice the payload, 10 times the range, and 70 percent lower operating costs, Electra claims.

Those benefits stem in part from distributed electric propulsion, wherein a small turbogenerator drives eight electric motors spread across the wing. Electra says this reduces emissions (by 30 percent) and noise (75 dBA at 300 feet, equivalent to a vacuum cleaner) below those of traditional airplanes or rotorcraft.

Since the aircraft uses hybrid power to fuel up—and to recharge its batteries during flight—airports won’t need electric charging infrastructure to accommodate it. That could be a crucial advantage for Electra when it comes time for the company to scale.

The eSTOL’s fixed-wing, rigid-propeller configuration—which eliminates hover and transition flight—gives it a path to be certified as a multiengine, Level 3, low-speed airplane under FAA Part 23. That means it could be flown with a standard pilot’s certificate in the airplane category.

In addition to passenger transport, on-demand urban air mobility services, and defense applications, Electra expects the eSTOL to handle cargo logistics, executive transport, humanitarian aid, disaster response, and a variety of other use cases. Its commercial launch is planned for 2028.

Topping the 2,000 preorder mark reflects the steady momentum Electra has enjoyed in recent months. That began in August with the announcement of fresh financing from climate tech fund Statkraft Ventures and the U.S. Air Force, the latter taking the form of an $85 million contract to develop and test a full-scale prototype. The following month, Electra completed the maiden voyage of its EL-2 Goldfinch demonstrator, marking the first flight for a hybrid eSTOL design.

December brought with it a major agreement with JSX, one of the world’s premier regional air carriers, which ordered as many as 330 hybrid-electric models. Those include 32 firm orders and 50 options for Electra’s nine-seater. The same month, customer Bristow Group placed a deposit for five early delivery slots for its 2021 order of up to 50 aircraft, representing one of Electra’s firmest commitments to date.

Bristow is expected to be Electra’s principal launch operational customer. The company at launch also has agreements to fly in the Middle East, Asia, Latin America, and Australia, among other locations.

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Aircraft manufacturer Electra.aero’s EL-2 Goldfinch demonstrator pays homage to its namesake’s golden hue. Unlike a bird, however, the hybrid-electric ultra-short takeoff and landing (eSTOL) aircraft took off from the runway like a conventional plane once on Nov. 11 and again on Sunday, marking its inaugural flights.

The former was an all-electric test. But Electra said the latter was the eSTOL design’s first in hybrid configuration. Both flights were piloted by Cody Allee, chief technology officer of ABSI Aerospace & Defense and a former U.S. Marine Corps pilot, at Manassas Regional Airport (KHEF) in Virginia.

“The first hybrid flight lasted 23 minutes, reached an altitude of 3,200 feet, and covered a distance of approximately 30 miles,” said JP Stewart, vice president and general manager of Electra. “We’re looking forward to further expanding the envelope of this aircraft and demonstrating the full capability of Electra’s technology.”

Electra said its two-seat Goldfinch demonstrator is the first blown-lift aircraft that uses distributed electric propulsion and a hybrid-electric propulsion system. Blown lift directs slipstream flows back over the wing into large flaps and ailerons. This directs flows downward to “multiply” lift, allowing the eSTOL to take off and land at “neighborhood driving speeds.” By the company’s estimate, the demonstrator needs just 300 feet of runway.

Unlike the tiltrotor design common to electric vertical takeoff and landing (eVTOL) models, Electra’s eSTOL has no hover or transition phase because it relies on fixed wings and rigid propellers. In addition to removing complexity from the design, the fixed-wing architecture gives Goldfinch a path to be certified as a multiengine, Level 3, low-speed airplane under FAR Part 23 and be operated with a standard pilot’s certificate in the airplane category.

The aircraft’s eight electric motors run on a small turbogenerator that uses hybrid-electric power to recharge its batteries. Electra says this reduces emissions (by 30 percent) and noise (75 dBA at 300 feet, equivalent to a vacuum cleaner) below those of traditional airplane or rotorcraft. There’s also the benefit of added range and payload, stemming from Goldfinch’s lack of reliance on ground-based electric chargers and the reduced energy requirements of blown lift.

The Goldfinch demonstrator that flew this month is a predecessor to Electra’s flagship, nine-passenger model for commercial and government customers. That full-scale design is expected to cruise at 175 knots for up to 500 sm (434 nm), while carrying twice the payload (up to 2,500 pounds) of eVTOL designs with the same energy requirements.

Its runway requirement is projected to be even shorter—just 150 feet, half the length of a football field. And all of this comes with the promise of 70 percent lower operating costs than “vertical alternatives.”

“The aim of Electra is to fill a gap in air travel between 50 and 500 miles, where most trips today are made by automobile,” said Electra founder and CEO John Langford. “The key to saving time is to operate close in, which means getting in and out of small spaces quietly and safely, while still being fast enough to cover long distances. Electra will be able to take you from downtown Manhattan not only to Kennedy Airport [KJFK], but to Washington, D.C. It will bring air service to thousands of communities where air travel today is not a practical or affordable option. It also opens vast new opportunities for middle-mile cargo logistics.”

The company so far has a backlog of more than 1,700 preorders of its flagship model from more than 30 customers, which it values at about $6 billion. Customers include Houston-based helicopter provider Bristow Group, airline Ravn Alaska, and Latin American on-demand private aviation platform Flapper. It also has plans to fly in Asia, Australia, and the Middle East.

In addition, Electra is developing a Goldfinch prototype for the U.S. Air Force under a contract with AFWERX, the department’s innovation arm. The agreement, worth up to $85 million, will see Air Force pilots take the aircraft out for testing and validation of operational use cases.

The Air Force has been a valuable partner for Electra, which as of August had six active Small Business Innovation Research (SBIR) and Small Business Technology Transfer (SBTT) Phase II and III contracts. Those agreements have allowed it to mature Goldfinch’s blown-lift aerodynamics, hybrid-electric powertrains, flight controls, and other features.

In addition to passenger transport, on-demand urban air mobility services, and defense applications, Electra expects Goldfinch to handle cargo logistics, executive transport, humanitarian aid, disaster response, and a variety of other use cases.

While the full-scale Goldfinch’s FAA certification isn’t expected until 2028, Sunday’s test flight was a promising development for Electra as it seeks to establish a new mode of regional transportation.

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From a literal standpoint, many examples of this concept jostled for attention on the static display and in the halls at the Paris Air Show at Le Bourget this year. But the distributed power demonstrated by CORAC-supported collaboration between major aerospace OEMs Daher, Safran, and Airbus on the EcoPulse project has also emerged as a theme in the drive toward a market-ready airplane.

CORAC stands for “le Conseil pour la Recherche Aéronautique Civile,” or French Aeronautic Research Council, a focal group in France leading the charge toward decarbonization. EcoPulse is also funded by the DGAC (France’s civil aviation authority) through France Relance and NextGenerationEU. While governmental motivation is critical, what powers a project toward real sustainability solutions is the will to commit precious workforce and material resources at the corporate and teams level.

What Is EcoPulse?

From a distance, the silhouette of the EcoPulse belies its basis on the Daher TBM airframe. Already an efficient utilizer of the Pratt & Whitney PT6-series turboprop engine, the TBM 900 formed a shell for the project with well-understood aerodynamics and serviceability as a baseline for the effort.

Daher was already “in anticipation” of the current climate on decarbonization for some time, according to head of aircraft design Christophe Robin, lead for the EcoPulse project for Daher’s team, with chief technology officer Pascal Laguerre. 

“We started to think about that five years ago, and at that time it was not a very common word—decarbonization—so we said we need to do something,” said Robin in a walkaround the airplane with FLYING. “But let’s make something very concrete. No PowerPoint, no things like that. Let’s build an aircraft—and let’s build an aircraft with partners, with people that have the technology that we don’t have as an aircraft manufacturer. Above 28 volts of electricity, we don’t know too much.

“The goal is not to modify a TBM. The goal is to put as much technology as possible on an aircraft, to make something which is probably completely stupid from a product point of view, but which makes sense from a technology point of view.” 

From this, the consortium would learn and capture immense amounts of data from which to draw conclusions that could inform a marketable initial product offering.

• READ MORE: EcoPulse Aircraft Headlines Daher’s Sustainability Initiatives

The project was announced at Le Bourget in 2019—the last occasion of the Paris Air Show—and work has taken place since then. Safran produced the six electric ENGINeUS motors (at 80 kwh each) mounted with e-Propellers distributed along the wings, three on each side. The props have two positions, one for normal flight, and one feathered. The propulsion system takes its power from two sources: a turbogenerator—an electricity generator powered by a gas-burning turbine—from Safran and a battery pack supplied by Airbus. The Power Distribution and Rectifier Unit protects the high-voltage network and distributes the available electrical power along with the high-voltage harnesses (all from Safran). That’s important, because the system manages a total capacity of 800 volts—a leap in electrical system management unprecedented in this type of vehicle.

“Hybridization and electrification are key to the aerospace sector’s decarbonization journey,” said Sabine Klauke, CTO at Airbus. “With EcoPulse, we learned a lot from developing the high-power battery pack entirely, from the monitoring system to the thermal runaway and short-circuit tests. Some of these key learnings are already applied in several of our demonstrators with the common ambition to lower emissions. We are now all eager to see this technology flying and continue to progress on our electrification roadmap.”

First Flight: Normal Power

The EcoPulse took its maiden flight in 2022 using its stock PT6A engine before the electrical system was operational. Ground and flight testing thus far in 2023—including 27 hours in flight—have gone toward proving the aerodynamics of the engine configuration along with the operability of its systems. The flight deck features a Garmin G1000 standard on the airframe, with additional avionics to support the new systems. The consortium looks forward to the first flight engaging the electric motors later this summer.

“The demonstrator has so far amassed around 27 hours of flight time with the electric propellers feathered,” said Laguerre of Daher. “Flight tests of the hybrid-electric powertrain are due to begin later this summer. We are going to learn a lot. From this demonstration program, we plan to develop our future product roadmap and basically spec the hybrid aircraft we intend to produce by the end of our five-year plan. We expect by the end of 2027 to be able to offer our first hybrid aircraft to the market.”

Eric Dalbiès, executive vice president of strategy and CTO for Safran, said: “After endurance ground test campaign for the e-Propellers, the first hybrid-electric flight with the six e-Propellers activated will be an important milestone for our technology roadmap as Safran’s objective is to position itself as the leader in future hybrid and all-electric aircraft systems.” 

“For us this project is a sweet sport,” Dalbiès added in the press briefing. “Whatever happens in the future, about the maturity of this kind of system, it’s really answering the goals of research and technology projects, to make a representative demonstration—full scale—of the complete system.”

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Electra.aero unveiled the eSTOL (electric short takeoff and landing) demonstrator at a special ceremony at 5 p.m. EDT Monday to present the concept and answer questions about both the technology and vision for its future use. According to the company, the aircraft represents the first use of blown lift using distributed electrical propulsion, allowing the airplane to to take off and land in short distances.

The two-seat airplane utilizes eight motors and an internal hybrid-electric power generator to recharge its battery system. The company plans to put the aircraft into a full flight test program this summer as it works towards a nine-seat production model. The production version is expected to begin testing in 2025. In all, the company anticipates the final version to carry 2.5 times the payload and exhibit a 10-times-longer range with 70 percent lower operating costs than vertical takeoff alternatives. Electra.aero claims this will transpire “with much less certification risk, proving that climate-friendly technology can also be cost-effective.”

• READ MORE: Electra eSTOL Developer Acquires Airflow

“In the three years since we founded Electra, we’ve designed our eSTOL aircraft, validated our blown-lift technology with a subscale demonstrator, and run a fully integrated test of our 150-kilowatt, hybrid-electric generator at full scale,’’ said John Langford, founder and CEO of Electra.aero. “Now we’re ready to test the entire system with this technology demonstrator aircraft. We can’t wait to fly this plane and show the world what our eSTOL aircraft can do.”  

Electra expects a 1,900-pound passenger and cargo load capacity, and it’s shooting for a 434 nm (500 sm) range.

Certification and Investor Backing

The idea is to give operators the best of both worlds—airplane and rotorcraft—with the capability to use similar spaces to land and take off. Entry into service is hoped for 2028, with the company seeking FAA Part 23 type certification by that time. Electra’s financial backing comes from a recent $30 million funding award from the U.S. Air Force as part of a total of $85 million it can draw from. The company also holds letters of intent from more than 30 potential customers, with a valuation of $4 billion if fully realized.

“Electra was founded to build electric aircraft that make sense,” said J.P. Stewart, vice president and general manager for Electra. “We are meeting market demand for cleaner, cost-effective aircraft that can fly people and cargo closer to where they want to go, and this technology demonstrator aircraft will prove that our eSTOL technology makes that possible.” 

Launch partners Bristol and Southern Airways were on hand for the rollout, along with representatives from the Air Force’s Agility Prime program. Ground tests will continue this month, with first flight anticipated later this summer.

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