Munich-based manufacturer Vaeridion on Saturday opened its electric battery development lab at the Bosch Collaboration Campus in Holzkirchen, Germany. The site, located in the Munich suburbs, grants Vaeridion access to hardware and services from Bosch General Aviation Technology—the GA arm of the multinational engineering firm—and ITK Engineering, which Bosch acquired in 2016.

Vaeridion will use the campus to develop powertrains, battery models, and cybersecurity compliance for its digital systems, as well as test and integrate its proprietary high-voltage batteries for its flagship Microliner. The facility will run the gamut of battery manufacturing steps, from individual cells to fully integrated modules.

In addition to Vaeridion co-founders Ivor van Dartel and Sebastian Seemann, the opening of the center was attended by Bavarian State Government Minister Florian Herrmann and Holzkirchen Mayor Christoph Shmid.

“Bavaria is proud of its vibrant startup scene, which benefits from the excellent ecosystem of science, research and technology-passionate policies,” said Herrmann. “Sustainable e-mobility is a future topic with a global market—the development of a battery-powered microliner is therefore a brilliant idea.”

According to a 2018 study, more than 80 percent of Germany’s population lives within 20 kilometers of a regional airfield. Vaeridion’s flagship Microliner is designed to connect those sites and provide a new option for underserved regions, saving customers multiple hours per trip, the company claims. It can also take off and land at large commercial airports.

The aircraft’s glider-inspired wing features a high aspect ratio, minimizing drag in cruise and producing a high glide ratio. The batteries, which can be charged in about 45 minutes, are integrated there rather than in the fuselage to optimize the aircraft’s weight and travel distance, Vaeridion says. The manufacturer claims its design flies with the lowest energy consumption for an aircraft seating up to nine passengers plus crew for distances up to 500 km (310 miles).

Working with Aircraft Design Certification GmbH, which owns design organization approval (DOA) from the European Union Aviation Safety Agency (EASA), Vaeridion hopes to certify the model as a GA aircraft before 2030.

By that year, the manufacturer intends to introduce the Microliner on commercial routes in Denmark in partnership with Copenhagen AirTaxi and Copenhagen Helicopter, both based out of Roskilde Airport (EKRK) in Copenhagen. The companies believe the design will be part of a digital platform that allows customers to plan, book, and pay for flights in one place.

“The new green aircraft type requires significantly shorter takeoff and landing distances than traditional aircraft, which allows the use of smaller airfields that are no longer utilized for commercial routes,” said Martin Winther Andersen, CEO of Copenhagen Helicopter. “These routes were abandoned as aircraft types gradually became larger. The Microliner can change that, allowing us to create a dense network of domestic routes again.”

In addition, Belgium and Netherlands-based operator ASL Group plans to utilize the aircraft for short-haul business routes. Aero-Dienst, the operation and maintenance provider for European automobile association ADAC’s fleet of ambulance helicopters, intends to deploy it for aircraft maintenance and air ambulance services.

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The manufacturer on Wednesday announced it completed the installation of an “automotive style” battery pack manufacturing line within its integrated test lab and manufacturing facilities in San Jose, California.

The production line is intended to complement the company’s air taxi manufacturing facility in Covington, Georgia, where it expects to initially produce up to 650 aircraft per year. The site remains under construction but is “on track” to be completed later this year, Archer reaffirmed Wednesday.

“This is a major milestone for Archer as designing, developing, and mass producing electric propulsion systems that are purpose built for electric aircraft is the key to unlocking the electrification of aviation,” said Tom Muniz, chief technology officer of Archer. “The facility will give us the capability to scale our battery pack production to meet the demands of the output that our Covington, Georgia, facility will be capable of.”

Each of Archer’s Midnight aircraft will run on six of the company’s proprietary lithium-ion battery packs, which power a dozen electric engines. The cylindrical cells within each pack deliver a higher level of safety, performance, and scalability than other form factors, Archer says. The packs are also equipped with a proprietary thermal runaway containment capability.

Archer’s new battery pack manufacturing line is designed to operate at full capacity from day one and, according to the company, is capable of producing up to 15,000 battery packs per year.

Certain portions of the manufacturing process—including cell testing and loading, adhesive dispensing, laser cleaning, laser welding, and end-of-line testing—have been automated. The manufacturer says this is intended to improve product quality and operator safety while making it easier to trace data across the manufacturing cycle.

Unlike the manufacturing strategy for the Midnight air taxi, which leverages outside suppliers to provide the majority of the aircraft’s components, Archer chose to vertically integrate battery cell design and production, building and assembling those components in house.

The battery packs in March successfully endured a series of 50-foot drop tests, a feat they will need to accomplish again during for-credit testing with the FAA. Similar to the 50-foot fuel tank drop test for rotorcraft and fixed-wing aircraft, the evaluation is meant to gauge the batteries’ ability to withstand a significant impact, which could cause a leak, fire, or explosion if the tech is not up to standard. Archer considers it to be one of the most challenging tests in the type-certification process for Midnight.

The manufacturer is also evaluating its battery pack technology with NASA via a Space Act agreement with the agency. Initial testing will gauge battery cell safety, energy, and power performance, studying how they might function in “extreme abuse cases.” The battery pack testing arrangement is just one portion of the agreement, Archer says.

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