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 WELCOME
here’s a bite in the morning

T
air and autumn is inching ever
closer. However old we get,
this is still very much ‘back
to school’ time and while the
AIR International team may
be a little long in the tooth for
new pencil cases, we have
transferred our enthusiasm for the latest kit to
the likes of shiny new aircraft and other clever
technology. This month we look at the latest
generation of start-ups and their innovations
(page 50), consider how three aircraft makers
– some new, some less so – aim to stay
competitive in a crowded market (page 36), and
take a close look at digital twinning and how it
is helping the likes of Boeing bring new types to
market faster and more cheaply (page 74).
When it comes to military aviation, the
opportunities for launching new equipment and
aircraft continue to present themselves. While
the Russian attack on Ukraine is now more
than seven months old, we are seeing renewed
tensions between China and Taiwan. A recent visit
to the latter by Nancy Pelosi, Speaker of the US
House of Representatives, led to an outburst of
military drills that provides some insight into how
China might attempt to seize the island. More
than 200 People’s Liberation Army Air Force
aircraft crossed Taiwan’s ADIZ, with war in the
Pacific looking ever more likely, according to Alan
Warnes, editor at large, modern military. However,
for now, we take a look at a new era of rotary
operations (page 68) and pay tribute to France’s
retiring C-160R, on page 44.
Whether commercial or military, we will
continue to keep you up to date with the latest
developments in aviation. As ever, enjoy the issue.
Journalists visiting Embraer find themselves ‘inside the belly of the beast’ on a KC-390 test flight Jorge Penalba
Tara Craig,
AIRLINER World AIRFORCES AVIATION News
Editor, AIR International
October covers Monthly October October looks
everything from reports on Italy’s into Delta’s
easyJet’s approach latest Typhoon Max 10 order and
to hydrogen as SAF to Flag exercise and talks to father
Spirit and Frontier’s provides an update and son attack
failure to merge on Crimea helicopter pilots

October 2022 AIR International 3

50
0 THIS
MONTH
32 06
COMMERCIAL NEWS
Manufacturers trim
2022 delivery goals
12
FACE TO FACE
Jon Page, Pexco
Aerospace president, tells

68
THE RAF’S E-7 WEDGETAIL PROGRAMME amid supply chain AIR International about the
Joe Campion provides insight into the RAF’s issues and LAX joins innovative AirShield
latest airborne early warning programme, TSA drone programme cabin-air wellbeing device
the Boeing E-7 Wedgetail

SEA KINGS, SAR AND MUCH MORE

08 16
36
An exciting new era in rotary operations is
under way on the UK’s south coast as Ian BUSINESS AS USUAL NUTS & BOLTS
Harding and Kevin Wills discovered when The Grob G180 returns BAE Systems’ new NetVIPR
visiting a specialist helicopter provider to the skies, Aerion’s ensures militaries are
assets are up for grabs, not solely reliant on fixed
and Challenger 3500 ground infrastructure
SMALL BUT PERFECTLY

80
delivery is imminent or satellites
FORMED COVER STORY
Craig West looks into Europe’s ‘mini airliner’
sector, in particular how three manufacturers
remain competitive in a congested market

TANKER TROUBLES
10MILITARY NEWS
18
LAUNCH PAD

50
The first prototype of NASA and Boeing plan
Tim Fish looks at the latest developments in
Italy’s next-gen attack Starliner’s first piloted
aerial refuelling – one of the key strategic
helicopter – Leonardo test flight to the ISS,
advantages an air force can have
Helicopters’ AW249 – and Orbital Reef passes
has its maiden flight a crucial review

86
BRIGHT YOUNG THINGS
From remote piloting to drones that can take
off in storms, some of the best technology at
Farnborough International Airshow was the
work of start-ups, reports Tom Batchelor
12
FIT FOR GROWTH
Jorge Penalba reflects on Francisco Gomes

56
Neto’s turbulent first years with Embraer, and
how the CEO and his team intend to steer the
company into calmer waters

ALIVE AND KICKING

The world’s most numerous attack helicopter,
the Mi-24/35 Hind is still in production in

SAVE
Russia, attracting continuing interest from
operators. Alexander Mladenov reports

BY SUBSCRIBING!
A subscription to
AIR International offers great
savings on the cover price October 2022 AIR International 5
See pages 30 and 31 for details
 ‘Real constraints’

TOP5
MAJOR AEROSPACE manufacturers have Calhoun said: “We continue to experience real
trimmed their 2022 delivery goals as they constraints. We're taking action to mitigate
grapple with supply chain issues affecting risk in a number of areas, including engines,
the industry. raw materials, and semiconductors…we're
COMMERCIALWEBSTORIES Airbus announced in its latest results in July increasing our on-site presence at suppliers,
2022 that its target is to deliver around 700 creating teams of experts to address industry-
1 A LOOK INSIDE THE TOP GEAR commercial aircraft by the end of this year, wide shortages, utilising internal fabrication for
BOEING 747 slightly down on the previously announced aim search capacity and managing inventory safety
of handing over around 720 jets. stock levels, and growing where needed.”
2 WHY BA A350-1000 SUFFERED Boeing has likewise revised downwards its Calhoun cited structural castings for engines
TAIL-STRIKE DURING GO-AROUND
annual delivery target for its 737 family. Boeing as a key issue: “Capacity is limited. It’s not just
3 TUI TAIL-STRIKE AT MANCHESTER president and CEO David Calhoun said during about money, it's qualification. It's one of the
AFTER “DISJOINTED” TRAINING the company’s Q2 earnings: “We now expect toughest components inside the supply chain
delivery to be closer to the low 400s for 2022, to ultimately get to a qualified status as well as
4 EXCLUSIVE: FULL REVIEW OF short of what we discussed earlier this year as just the sheer physical capacity to do it.”
FIRST-EVER NORSE FLIGHT we drive stability and predictability.” Noting that the industry needs to moderate its
Disruptions to supplies of engines and output rates to ensure it is ahead of the issues,
5 EMIRATES RESUMES FLIGHTS electronic components have caused the issues. Calhoun added the supply constraints mean
TO THIRD LONDON AIRPORT Airbus CEO Guillaume Faury told the Financial Boeing is unable to hike production rates as
Times: “We are trying to go as fast as we can it originally predicted. “We're going to watch
WWW.KEY.AERO [building aircraft] but have to recognise the as they qualify more capacity before we pull
environment for what it is.” those rates up.”
 COMMERCIAL
NEWS
BY MARK BROADBENT

Dreamliner
deliveries

Lufthansa’s first 787-9 on its delivery flight Boeing

BOEING IS handing over 787 Dreamliners for the
first time since May 2021 after the US Federal
Aviation Administration (FAA) approved production
changes to address manufacturing issues.
The FAA said Boeing “has made the necessary
changes to ensure that the 787 Dreamliner meets
certification standards”. The agency “will inspect
each aircraft before an airworthiness certificate is
issued and cleared for delivery”.
Boeing suspended 787 deliveries after improperly
filled joins on fuselage components, the tailfin and
the forward pressure bulkhead were identified on
undelivered aircraft, along with inspection and
quality-control concerns.
Boeing intends to gradually build back to
a production rate of five aircraft per month,
although the supply chain issues affecting aircraft
production more widely are also likely to have a
bearing on its output.
American Airlines received the first Dreamliners
(both 787-8s) to be delivered from Boeing’s North
Airframe OEMs are having to cope with major supply chain issues Pascal Pigeyre/Airbus
Charleston plant after the pause. Lufthansa
received its initial Dreamliner in late August.

LAX tackles drones The agency aims to expand the capability to other
airports in the future and raise awareness of the risks
AEROFLOT IS to acquire more than 300 Russian
commercial aircraft, according to a Kremlin transcript
of a meeting between Sergei Aleksandrovsky, head
of encroaching on restricted airspace.
of the airline, and Russian president Vladimir Putin.
According to the TSA, the drone detection technology Aeroflot is seeking to purchase 210 Irkut MC-21s, 73
operates 24 hours a day, and is capable of using radio Sukhoi SSJ-100 Superjets and 40 Tupolev Tu-204s.
frequency waves, electro-optical, radar, acoustic and
thermal imaging to identify a UAS’s precise location.
There have been approximately 90 visual sightings START-UP Hill Helicopters has pushed back the first
and 5,200 technical detections within three miles of the flight of its HX50 helicopter to late 2023 or early 2024,
the company disclosed. Hill is focusing on maximising
LAX has recorded 38 drone sightings in 2022 LAX LAX perimeter since the start of 2021 and 38 sightings vertical integration (producing everything in-house)
in 2022 alone, the agency says, including one incident in a new UK factory. It has sold 627 helicopters (516
LOS ANGELES International Airport has joined the where a drone flew within 700ft of an aircraft. HX50s and 111 HC50s, the commercial version).
United States’ Transportation Security Administration’s A similar project underway at Miami International
(TSA) UAS Test Bed Program evaluating technology to Airport since summer 2021 has “detected thousands of
detect, track and identify unmanned systems entering UAS flights in the vicinity of the airport”. The agency is MAMMOTH FREIGHTERS has signed a multi-year
contract with Aspire MRO to perform 777-200LRMF/-
restricted airspace. continuing to collect data there.
300LRMF passenger-to-freighter conversions at Fort
Congresswoman Lucille Roybal-Allard said the trial LAX was chosen as a test site “due to [its] diverse Worth’s Alliance Airport. Mammoth is “developing a
will “validate the effectiveness of UAS detection aviation operations, large number of enplanements, global production and conversion site network”
technology in real-world aviation environments”. frequency of UAS activity, and high passenger volume”. including conversion capacity at two other sites.

October 2022 AIR International 7

 Challenger ON AUGUST 8, Bombardier announced that
Air Corporate had placed a firm order for a
Challenger 3500 super-midsize business jet.
Bombardier plans to ramp up production next
year by 15-20%. It aims to deliver 120 aircraft
across its portfolio during 2022, and by the end

3500 arrival The Italian firm will become the first to offer the
revised design for charter services in Europe.
Air Corporate president Roano Grandi said of
of June had handed over 55 business jets.
The manufacturer announced the Challenger
3500 on September 14, 2021, as a refinement

imminent the deal: “This exceptional aircraft provides us

with an outstanding option to further enhance
our charter business and provide our discerning
of the Challenger 350, designed to keep it
competitive in the hotly contested midsize
category. In addition to adding autothrottles
customers with an exceptional private aircraft as standard, upgrades to the cabin include
experience at every level.” Air Corporate what Bombardier claims to be the industry’s
operates from eight locations within Italy. first voice-controlled cabin to manage lighting,
Delivery of the first Challenger 3500 is due temperature, and entertainment systems via
before the end of September. Bombardier an app on personal devices, and wireless
president and chief executive officer Eric Martel charging for electronic devices through pads
confirmed that the programme was on track located in the side ledges adjacent to forward-
while reporting the manufacturer’s second facing seats. Passenger comfort is improved
quarter results on August 4. in comparison to the 350 by lowering of the
All certifications required for the aircraft have cabin altitude at Flight Level 410 to 4,850ft.
been received. These include approval for the The launch customer for the aircraft is Les
Safe Flight autothrottles and the Nuage seats, Goldberg, chairman and chief executive officer
first introduced in the Global 7500 and later of Entertainment Technology Partners, which
adopted for the Global 5500 and 6500. has its headquarters in Orlando, Florida.

Citations top
Q2 deliveries

The second quarter of this year saw 48 Cessna Citations delivered, among them 11 Latitudes (to 21 by the end of June) Textron Aviation

Grob G180
RECENT FLIGHT test activity undertaken by a surviving 41,000ft, with a maximum ceiling of 45,000ft, have
Grob G180 SPn indicates that the utility jet project is an endurance of about seven hours and range of
moving forward, albeit not in the role originally intended 3,400km. With the exception of the maximum ceiling,

back in the air when it was conceived in 2004.

In June, the third G180, D-CSTT (c/n 90003), was
noted conducting flight tests at Memmingen, Germany.
these figures are within the capability of the original
G180. Production is expected to be undertaken at a
new plant to be established by TASL. According to
The aircraft is understood to have recently adopted its Scramble, the Dutch Aviation Society: “This would be
current German registration, having previously been the first time that an Indian private entity is looking at
F-WINT. Notification of the change of identity was making a full military-grade aircraft, which until now
originally recorded on May 15, 2020. has been the domain of the state-owned Hindustan
By February 2021, Tata Group of India had acquired Aeronautics Ltd (HAL).”
the intellectual property rights to the aircraft. At the The aircraft is the third of four G180 prototypes that
time, it was announced that the company’s Tata were completed. The first, D-CSPN (c/n 90001), is on
Advanced Systems Ltd (TASL) division planned to use display at Oberschleißheim near Munich, Germany, as
the platform as the basis for a military intelligence part of the Deutsches Museum collection, where it was
gathering system for India. delivered in 2012. The second, D-CGSP (c/n 90002),
Grob Aerospace previously studied a high-altitude was destroyed in the crash near Mindelheim-Mattsies
long endurance concept based on the G180 known as Airport on November 29, 2006, that claimed the life of
the G600, which featured longer span, high-aspect Grob’s chief test pilot, 45-year-old Gérard Guillaumaud.
ratio wings and significant alterations to the rear D-CSPG (c/n 90004) first flew in August 2008 and
fuselage. Reports differ as to which version TASL is was withdrawn by the end of the year at Mindelheim-
basing its design on, but it is expected to operate at Mattsies after Grob Aerospace entered insolvency.
 BUSINESS
AS USUAL
BY DAVE WILLIS

Aerion assets
up for grabs
A DEADLINE for bids for the assets of the defunct
Aerion Corp has been set for September 7
by Development Specialists, Inc (DSI). Aerion
Bombardier expects to start delivering Challenger 3500s in September 2022 Bombardier ceased operations in May 2021, after spending
nearly two decades researching technologies
for a supersonic business jet, the Aerion AS2.
DELIVERIES OF new business jets increased 9.5% in Citation Sovereigns delivered, amounting to 72 DSI, a management consultancy and financial
the first half of 2022, according to the latest report aircraft. Textron Aviation reported that its backlog advisory firm with offices throughout the US
released by the General Aviation Manufacturers had grown by $708m to $5.8bn, but cautioned that and in London, was appointed by a Florida court
Association. A total of 171 aircraft were handed problems in the supply chain remained, and could on July 12 to oversee the sale of the company’s
over in the second quarter, making 289 aircraft in push some deliveries into 2023. assets under the state’s statutes. The process
the first six months of the year. Bombardier delivered one fewer aircraft in the is being overseen by Joseph J Luzinski, a senior
Just under a third of the jets were members of second quarter of 2022 compared to 2021, handing managing director at DSI. The assets were due
the Cessna Citations business jet family. Textron over 28 business jets (12 Challenger 350/650s and to be sold on September 16, with all proceeds
Aviation released its results for the quarter on July 16 Globals) during the period. This was an increase going towards paying off Aerion’s creditors.
28. It reported that it had delivered 48 Citations, of three Challengers and one fewer Global. Pilatus The disposal of the assets marks the end of
four more than in the second quarter of 2021 and 15 handed over 12 PC-24s in the second quarters Aerion, which, regardless of its demise, played
above its figure for that half-year. These comprised of both 2021 and this year. As noted last month, an important role in promoting the return of
eight Cessna 525 Citation M2 Gen2s (to 16 by the Dassault shipped 14 Falcons, Embraer 21 Phenoms civil supersonic travel. The Reno, Nevada-based
end of June), seven 525B Citation CJ3+s (one and Praetors, and Gulfstream 22 business jets. company halted work on the Aerion AS2 because
fewer than in the first quarter), nine 525C Citation Cirrus delivered 19 SF50 Vision light personal of difficulties raising the finance to complete
CJ4 Gen2s (to 16 this year), five 560 Citation XLS+ jets, for a total of 30 by the middle of this year. production of the aircraft. It had teamed with
Gen2s (two more than the last quarter),; 11 680A Honda shipped six HA-420 HondaJets in the last GE Aviation to develop the Affinity, a twin-shaft,
Citation Latitudes (to 21 by the end of June) and quarter, equalling its figure for the first six months medium bypass power plant in the 71.2-89.0kN
eight 700 Citation Longitudes (adding to the three last year. In the large airliner-derived sector, range, which could meet civil requirements for
delivered earlier this year). In comparison, in the Airbus Corporate Jets delivered a single ACJ330- supersonic operations, including stringent noise
first half of 2021, the totals for the six models were 300 during the quarter. Boeing Business Jets has and emissions criteria. GE Aviation is the largest
16, 11, 12, 9, 13 and 8, plus the last three 680 yet to deliver an aircraft in 2022. of the creditors, owed approximately $32m, but
others include Spirit AeroSystems and Boeing,
the last of these having provided financial,
engineering and industrial resources to advance
the programme.
While the physical assets left in the wake of
the demise of the company are few – mainly
computers, test equipment and wind tunnel
models of its designs – its intellectual property
is likely to be of interest to several aerospace
firms. This includes proprietary software and
a number of US and overseas patents. Aerion
spent significant time and money researching
supersonic laminar flow technology and boom
mitigation technology, as well as other aspects
of high-speed flight, which are of interest to
other companies working in the field.

The first prototype of the Grob G180 SPn utility jet Dave Willis

October 2022 AIR International 9

 Italy’s AW249
completes first flight
TOP5
THE FIRST prototype of Italy’s next-generation Italian Army Aviation Command’s) ageing fleet
attack helicopter – Leonardo Helicopters’ of AgustaWestland AW129C/D (AH-129C/D)
AW249 – has completed its highly anticipated Mangusta gunships. As part of this contract,
maiden flight at Vergiate Airport near Milan in the company will produce one AW249 prototype,
MILITARYWEBSTORIES northern Italy. Wearing the Italian test serial as well as three pre-serial production aircraft.
CSX82069 and painted only in primer, this The Italian MoD has so far confirmed that the
1 HOW IRAN MANAGES TO KEEP ITS gunship prototype was rolled out from its AW249 will be fitted with Leonardo subsidiary
F-14 TOMCATS FLYING hangar at Vergiate on the morning of August 19 OTO Melara’s TM 197B Light Turreted Gun
and successfully completed what is believed to System, a chin-mounted 20mm rotary cannon
2 NATO CONFIRMS LENGTH OF be the type’s first flight before 1200hrs (local – which can already be seen fitted to the
FAIRFORD B-52 DEPLOYMENT
time) the same day. The aircraft then performed prototype (CSX82069) in the images of its first
3 USAF RECEIVES FINAL ‘ZOMBIE a second flight early that afternoon. flight. The helicopter will also inherit RAFAEL’s
VIPER’ FROM BOEING Leonardo Helicopters made no official Toplite targeting system and Spike anti-tank
announcement regarding the first flight, but guided missiles from the outgoing
4 EXCLUSIVE: ITALY’S NEWEST ATTACK has been quietly working on the AW249 since it Mangusta fleet.
HELICOPTER COMPLETES FIRST FLIGHT was awarded a €487m multi-year development Despite still being in development, the AW249
contract by the Italian Ministry of Defence has already garnered interest on the European
5 USING GLASS TO REDUCE (MoD) under the nation’s New Exploration export market. In July 2018, Leonardo signed
OBSERVABILITY IN THE F-16 Escort Helicopter (NEES) programme in a letter of intent with Poland’s state-owned
January 2017. The NEES deal covered the study, Polish Armaments Group (PAG) to collaborate
WWW.KEY.AERO development, industrialisation, production and on the rotorcraft’s development. Poland is
testing of an all-new, next-generation attack currently seeking to replace its fleet of
helicopter, which has been designed to replace Soviet-era Mil Mi-24D/V Hind-D/E attack
the Comando Aviazione dell’Esercito’s (AVES – helicopters under the Kruk programme.
 MILITARY
NEWS
BY THE AI TEAM

US approves sale of
40 UH-60Ms to Australia

A S-70A-9 Black Hawk in Queensland Australian Army

US STATE Department approval has been granted

for the possible $1.95bn foreign military sale to
the government of Australia of 40 UH-60M Black
Hawks. An announcement by the US Defense
Security Co-operation Agency (DSCA) on August 25
confirmed the approval and said that US Congress
had been notified the same day. The deal also
includes a wide range of additional equipment,
spares, training and support.
The proposed sale will replace Australia’s current
MRH90 Taipan multi-role helicopter fleet with “a
more reliable and proven system that will allow
Australia to maintain the appropriate level of
readiness to conduct combined operations” the
DSCA said. Australia had been dissatisfied with the
performance of the MRH90 and Defence Minister
Peter Dutton announced last December 10 that the
nation was looking at purchasing the UH-60M to
AW249 attack helicopter prototype CSX82069 completes the type’s maiden flight Jeroen van Reijmersdal replace the 47 MRH90s in Australian Army service.

Initial Qatar Typhoons arrive (MS002, ‘RR9673’) and QA407/ZR508 (MS004, LOCKHEED MARTIN was awarded a $503,718,672
‘RR9671’), However, shortly after leaving, QA407 US Naval Air Systems Command foreign military sales
contract on August 29 for the production
encountered a problem with the in-flight refuelling (IFR) and delivery of 12 MH-60Rs for the Royal Australian
probe and was forced to return to Warton, leaving just Navy (RAN). Work is expected to be completed in
two aircraft to complete the flight to Qatar. They made October 2026.
an overnight stop in Athens, Greece, before continuing
to Qatar on August 26. A formal welcoming ceremony
for them was held at Dukham-Tamim Air Base, Qatar, LATVIA’S MINISTRY of Defence announced on
on August 28. Support was provided by Voyager KC2 August 15 that it had donated four helicopters to
ZZ338 (‘RR9260’), which came out of its base at RAF Ukraine. They comprised two Mil Mi-2MSBs and
Three Qatar Typhoons prepare to leave Warton Ian Lane two Mi-8MTV-1s (Mi-17s), which have already
Brize Norton, Oxfordshire.
been delivered and will shortly be integrated into
BAE SYSTEMS has delivered the first Qatar Emiri Air A few days later, on August 30, QA407 finally
Ukrainian Air Force service.
Force (QEAF) Eurofighter Typhoons. A formal roll- managed to get out of Warton after its IFR probe
out ceremony was held at the manufacturer’s UK problem had been rectified. It left accompanied by a
production facility in Warton, Lancashire, on August 15. second aircraft, QA406/ZR507 (MS003), both flying
The first four aircraft were due to depart from Warton initially to Tarbes, France, then on to Malta, where they EIGHT H-1 helicopters are to be donated free-of-
charge to the Czech Republic by the US. The dona-
on August 25, but on the day only three of the four arrived that evening before continuing the day after,
tion was confirmed on August 19 by Czech Defence
were ready for delivery. to Qatar. The next aircraft, ZR508 (MS005), made its Minister Jana Cernochová. They will comprise six
The aircraft that departed on that date were QA404/ maiden flight at Warton on June 17. The total order is AH-1Z Vipers and two UH-1Y Venoms, joining. four
ZR505 (MS001, callsign ‘RR9672’), QA405/ZR506 for 20 single-seat and four twin-seat aircraft. and eight, respectively, already on order.

October 2022 AIR International 11

 JON
PAGE
Pexco Aerospace
president Jon
Page talks to Mark
Broadbent about the
AirShield cabin-air
wellbeing device

A
erospace component
manufacturer Pexco
Aerospace recently
acquired AirShield from
Seattle-based design
company Teague, after
spending two years
taking the air management system from
concept to a proven technology.

Q How has COVID-19 changed the

game for onboard wellbeing?
The pandemic brought a need for improved
passenger wellbeing in the cabin. We
were dealing with an invisible enemy that
moved in unexpected ways and left many
passengers feeling uneasy about flying. The
industry has had to adjust quickly. Hygiene
and privacy are as crucial to the onboard
experience as comfort and safety. The next
generation of cabin interior innovations
will be centred on enhancing passenger
wellbeing in the cabin, and AirShield is
leading the charge.

Q How does AirShield work?

Installed over standard passenger air vents,
AirShield works with the existing HEPA
FACE
TO FACE
BY MARK BROADBENT

“We were dealing

with an invisible
enemy that moved in
unexpected ways”

October 2022 AIR International 13

CLOCKWISE FROM RIGHT:
AirShield redirects purified air around each
passenger to create protective air barriers

AirShield adapts airflow using existing vents to

restrict particles from passing into passengers’
personal space

Pexco 3D-printed iterations of AirShield during

development

AirShield uses existing HEPA filters

All images Pexco Aerospace

filtration system to personalise passenger technology. This was mounted on the side
airflow, redirecting purified air around and Q How will it meet passenger needs? wall air inlet and directed airflow downward.
in between each passenger to create There is a strong desire for an additional While very effective on some cabin interiors,
protective air barriers. level of personal protection, especially in testing showed we needed to incorporate
Its specially designed nozzle tips harness economy class. In the absence of visual and control air from the passenger vents.
Bernoulli’s principle [where an increase in cues like face masks and empty middle We began discussions with Teague,
the speed of a fluid occurs alongside a fall seats, AirShield delivers the effective, before purchasing the AirShield IP and
in static pressure or in the fluid's potential perceptible, and lasting change that overhauling its design.
energy], drawing in surrounding cabin air post-pandemic travellers want.
and doubling the resulting airflow. These It hits those two core desires for Q What engineering was involved?
air barriers drastically minimise the sharing enhanced hygiene and privacy – We had to consider how airborne particles
of exhaled air and ensure that every stopping unwanted odours and germs behave in a full cabin. We have spent two
passenger seated onboard breathes only entering personal space and creating a years using CFD and on-wing tests to
the purified air meant for them. ‘virtual distance’ where a physical one analyse how particles from every sneeze,
AirShield creates uniform airflow is impossible. There is also an added breath and cough move around the cabin,
throughout the cabin and, using wellbeing benefit for cabin crew as more especially among maskless passengers.
computational fluid dynamics (CFD) and passenger air is purged from the cabin. The HEPA filtration system ensures
on-wing tests aboard 737 and A320 purified air is streamed into the cabin
aircraft, has been proven to reduce every few minutes. By adapting the airflow
shared air particles between neighbouring Q Where did the idea come from? using the existing vents, we can enhance
passengers in an economy cabin by 76%. In early 2020, Pexco was independently its performance and restrict particles from
The technology is 50% quieter than working on a new way to enhance air passing into passengers’ personal space.
standard air vents, and does not alter the management in the cabin, developing Sending particles to the HEPA filters and
cabin’s temperature or volume of air. a patent for our original Air Diverter replacing them with fresh air is also faster.
 FACE
TO FACE
BY MARK BROADBENT

We prototyped more than 20 versions The data gathered during this process
of AirShield, which were 3D printed. informed the engineering development.
These rapid iterations empowered our
engineering team to constantly refine the Q What is necessary for certification?
technology and ensured we could achieve Certification is probably the biggest hurdle
the desired impact without modification in getting innovations into the skies.
to the existing airflow system or any You need experienced engineers to
recertification to the seating. manage every process step, working with
The result is AirShield’s unique three- regulators like the FAA and its designated
piece assembly that weighs less than 1lb, engineering representatives.
is incredibly durable, and quick and simple AirShield has entered the final stage of
to install during routine maintenance. We FAA certification and has been granted
have also added an antimicrobial material. a project specific certification plan
number. We are undergoing final testing
procedures, with full STC certification for
Q What testing has taken place? the A320 expected by October 2022.
Our work has included cabin airflow,
decibel level, g-force and flammability
testing. We completed extensive on-wing Q What airline interest is there?
tests aboard the A320 in partnership Airlines understand the world has changed,
with airlines including American Airlines, and so have passenger expectations.
Southwest Airlines and Alaska Airlines. We are in discussions with key airlines
We then partnered with Avolon in and OEMs to have the first AirShield
on-wing tests as part of FAA certification. installations in early 2023.

“Certification is the
biggest hurdle in
getting innovations
into the skies ”

October 2022 AIR International 15

NUTS
& BOLTS
BY MARK BROADBENT

PLUG AND PLAY

SECURE COMMUNICATIONS are essential in military
operations, linking commands, manned aircraft,
unmanned systems, ground combat vehicles,
maritime and electronic warfare assets and the
increasingly important cyber and space domains.
BAE Systems’ Digital Intelligence division recently
launched NetVIPR, a secure communications
network capability ensuring that militaries are
not solely reliant on fixed ground infrastructure
or satellites. According to BAE, the system
means they will be “much more able to sustain
a communications network through a myriad of
offensive challenges.”
NetVIPR is made up of a series of nodes across
a full spectrum of communications infrastructure,
each of which can add, access and move data.
“This means that even if some nodes are damaged
in warfare, the rest automatically re-route to
maintain optimum network speed and flow of
information, making it highly resilient,” said BAE.
The deployable ‘plug and play’ configuration
of NetVIPR is different from traditional military
networks, which usually rely on hardware being
set up and then maintained to provide functionality.
NetVIPR can also be updated from remote locations
“providing uninterrupted network access and data
transmission”, BAE said, adding that the system
works with existing communications hardware
found in most military platforms.
BAE has demonstrated NetVIPR’s capability on a
range of equipment and integrated it with existing
military radio systems, with other demonstrations
carried out on the network management interface.
Digital Intelligence is one of BAE Systems’ newest
areas. Launched in 2022, it is home to 4,800 digital,
cyber and intelligence experts in 16 countries.
The division combines digital capabilities from
across the BAE Systems Group, including the
whole of BAE Systems Air’s Applied Intelligence,
In-Space Missions, Defence Information and PPM
(Pulse Power and Measurement). According to
BAE: “Digital Intelligence collects, connects and
understands complex data, so customers can make
decisions and act quickly in the most demanding
environments. Governments, nation states, armed
forces and commercial businesses can maximise
their technological achievements to tackle the
evolving challenges of the digital age.”

The NetVIPR secure communications network

capability BAE Systems

October 2022 AIR International 17

QUANTUM SATELLITE
EUROPE’S FIRST commercial satellite
capable of being fully reprogrammed in
space is now in use. The Eutelsat Quantum’s
beams can be redirected to provide
information to people on moving vehicles in
close to real time. The project involved ESA,
the UK Space Agency and Airbus. ESA

SOLAR ARRAYS
LOCKHEED MARTIN,
Astrobotic Technology
and Honeybee Robotics
have won NASA contracts
to build prototype solar
arrays to help power human
and robotic exploration
of the Moon. NASA is
supporting development of
deployable arrays that can
autonomously deploy up
to 32ft high and retract for
relocation. NASA
LAUNCH
PAD
BY MARK BROADBENT

STARLINER TARGETS
NASA AND BOEING will undertake the first piloted
test flight of the CST-100 Starliner capsule to
the International Space Station (ISS) in February
2023. The scheduling follows the unpiloted Orbital
Flight Test 2 (OFT-2) mission, which launched
the vehicle, manoeuvred it in orbit, docked it with
the ISS and returned it to Earth.
Mark Nappi, Boeing VP and manager for the
Starliner, described OFT-2 as “very successful”.
The final report from the mission is being
completed, but the flight has led to what Nappi
called “fine-tuning” for the Crew Flight Test. This
includes tweaking timing and tolerance settings
in the propulsion system, specifically on the
spacecraft’s Orbital Maneuvering and Attitude
Control and Reaction Control System thrusters.
OFT-2 also identified revisions required
in several areas before the crewed flight –
principally the software for Starliner’s VESTA
(Vision-based, Electro-Optical Sensor Tracking
Assembly) sensors (which feed data to the flight
computer to guide the spacecraft in for docking),
as well as mission planning and crew training.
Starliner is Boeing’s crew transportation system
for regular flights to and from the ISS. Boeing
is contracted under NASA’s Commercial Crew
Program to resupply the ISS using the CST-100
(and United Launch Alliance Atlas V launcher).
SpaceX with its Falcon 9 rocket and Crew Dragon
has already flown crewed missions to the ISS
under the programme.
Once Boeing’s capsule is certified for long-
duration missions, the plan is that Starliner and
Dragon spaceships will alternate on the ISS
resupply schedule.
After the Starliner Crew Flight Test, NASA hopes
to fly the first operational six-month Starliner
crew rotation mission to the ISS with four
astronauts later in 2023.

LEFT:
Boeing’s Starliner spacecraft approaches the
International Space Station on the unpiloted Orbital
Flight Test 2 mission in May 2022
NASA
October 2022 AIR International 19
CORNISH LAUNCH
VIRGIN ORBIT confirmed its
next launch will be from the
UK’s Spaceport Cornwall,
followed by another from its
Mojave Air and Space Port
base in California, making
a total of four launches for
2022. The company recently
received a launch licence in
Brazil and signed an MoU
with J-Space in South
Korea. Virgin Orbit
 LAUNCH
PAD
BY MARK BROADBENT

REEF IN SPACE
ORBITAL REEF, the start-up aiming to put a
commercially developed, owned and operated
space station into low Earth orbit (LEO), has
successfully completed its System Definition
Review (SDR) with NASA.
The SDR establishes what the developer
called the “functional baseline” for the station,
demonstrating to NASA that the station design is
“feasible and achievable while validating that the
Orbital Reef system is on track to proceed into
the design phase.”
It involved an extensive review to ensure
the proposed space station architecture is
“responsive to the functional and performance
requirements.” The SDR also looked at the
proposed system architecture and the “flow-
down to all functional elements of the Orbital
Reef system.”
Representatives from Orbital Reef and NASA
participated in the SDR, conducted between
mid-June and mid-July 2022 to enable in-depth
reviews of documentation and feedback.
Sierra Space and Blue Origin are leading the
Orbital Reef project. Other partners include
Amazon Supply Chain, Amazon Web Services,
PLANETARY DEFENCE Arizona State University, Boeing, Genesis
SEPTEMBER 26, 2022, will see NASA conduct Engineering Solutions and Redwire Space.
its Double Asteroid Redirection Test on the Orbital Reef is working with NASA on developing
asteroid Dimorphos to prove that a spacecraft its space station under the agency’s Commercial
can autonomously navigate to and intentionally Low-Earth Orbit Development programme,
collide with a target asteroid. The aim is to launched in December 2021 to shift NASA
better prepare for an asteroid that might pose research and exploration activities in LEO to
an impact hazard to Earth. NASA/Johns Hopkins commercial organisations.
APL/Steve Gribben The company envisages “multiple new markets
in space” for its space station. Tourism is the
most eye-catching, but Sierra Space CEO Tom
Vice said this wasn’t the only objective: “It is
about unlocking the next great discoveries using
the microgravity factories that we will build
just 250 miles above the Earth’s surface. The
microgravity factories and services provided by
Orbital Reef could revolutionise every industry.”

TOP:
Orbital Reef’s low Earth orbit space station
Blue Origin via Orbital Reef

October 2022 AIR International 21

 the drone coverage we see in the United
States is of our own drones. As anyone who
watches the evening news can attest, the
US has used drones for 20+ years in its wars
against terrorist organisations. We have also
all heard about Israel's pioneering use of
drones in the Baka Valley to destroy Syrian
SAM batteries.
Your coverage alluded to Russia's use of
Israel-based drones in Syria as being very
successful, but I've never seen any other
source mentioning this.
The latest coverage of the Azerbaijan vs.
Armenia war was interesting in that they
appear to be peers in military terms, but
one side, Azerbaijan, made maximum use of
drones, while the other, Armenia, appeared
to make no use of drones or be able to
defend against them. I find this situation
hard to understand.
There is so little coverage of the specifics
of Russian drones, and their history, that
The NGF element of the Franco-German-Spanish FCAS/SCAF programme Key Publishing I find it next to impossible to comment
on their future use by the Russians in any
environment. If you look at US usage you
Not the time for divestment is war with Russia, the Kremlin will not will see that all the success is against third
In light of the current war between Russia be confronted by one air force, but the or fourth-rate countries. No real air forces or
and Ukraine and the likelihood that Vladimir 29 that make up NATO, plus other allies. SAMs and/or AAA. Even with that success
Putin has plans for Moldova and/or The majority of the frontline fighters and there appeared to me far too much use of
Lithuania and Poland, I don’t think we bombers are interoperable, that should high-tech aircraft in situations where even
should be complacent. It’s true the first of make up for any weaknesses that any one the current generation of drones appears to
the Type 26 frigates will be launched this aircraft might have. The RAF will never be more than adequate for the task. I think
year, but they are a long way off service. fight alone again, it’s all about a united the biggest question yet to be answered by
Same goes for the RAF. Now is not the time front, an allied front now. any military is whether today’s drones would
to be divesting ourselves of fighters. The F35 Yes, the F-35 is a long way off maturity, survive in a ‘near peer’ situation? I think that
is a long way from maturity, for instance with but it could still do a very good job working is the key question to be asked of today's
Meteor. The only thing that despots under- with Eurofighter Typhoons, F-22A Raptors, drones, no matter who manufactures or
stand is force – we need to make it Rafales, Gripens and Hornets on the uses them. In my opinion, today's evidence
clear any attack will hurt. offensive front. Even when the F-35 is indicates the current generation of drones
It's been said before, "In times of peace, mature it will not fight alone, but alongside will not survive in ‘near peer’ situations.
prepare for war". The trouble is nobody other NATO assets – hence fourth/fifth- Robert C Walker
appears to understand this. generation fighter integration. By email
On a separate matter, in terms of your Yes, there can be friction between
coverage of the indigenous aerospace the partners, as there has been in the
industry, it is a simple fact that no one Eurofighter – more in the early days than
Just pie in the sky?
country can afford the cost of developing now, but as you said one government could Maybe you will consider the following
an aircraft for its own needs. This inevitably not develop a new fighter on its own. If one thoughts excessively cynical – but here goes!
causes friction amongst partners all asking country did, it would probably be France Over the last few issues of AIR International
specific different tasks of the proposed who eyes Germany with a little suspicion, (and other related magazines) I have the
airframe. You then end up with a particularly when it comes to trying to feeling that the aviation world is totally living
compromise. Does this work? export a fighter to the likes of Saudi Arabia, in a dream world – ‘Dream Chasers’ being
Frankly, history tells us otherwise. which Germany wouldn’t currently allow. an apt terminology for Sierra Space’s craft
Hence the reason why the likes of Boeing Although this might change. (AIR International June/July 2022). That is all
and Lockheed have been so successful. Alan Warnes talk about possibilities that will only come to
Whether the likes of Tempest can buck this Group editor at large, fruition, if at all, in ten years or more.
trend is in the lap of the gods. Modern Military First and foremost is the clamour from
Richard Gunn airlines and other users to be seen to be
By email caring about using sustainable aviation fuel
On equal terms (SAF) – where and how are we ever going
With regards to divestment, if the Your May 2022 coverage of Russian drones to be able to produce sufficient quantities
unthinkable should ever happen and there was very interesting in that almost all of to replace present fossil fuel usage? I do
 CHECKING IN
BY OUR READERS
agree that the only realistic alternative is in the June/July issue, “by 2035 I want to Do you hold a passionate opinion
hydrogen-based fuels, but that approach see Tempest flying…” and later in the same about a civil or military aviation issue
has a long way to go. article “SCAF – ready for service by 2040 or a view on AIR International’s
And moving on, we are always being – but may slip”. I am afraid that both the content? We are listening. Particularly
informed about the 'next contestant' signing Tempest and SCAF have already become in such extraordinary times, we enjoy
on in the field of urban air mobility and cash cows with no sense of direction a lively dialogue with you through our
introducing another ‘vehicle’ usually already or control. news, features and analysis.
with hundreds ordered based on a sketch Alan Woof
and a new idea. By email
All of them rolling along with no thought with
regards to air traffic control or the potential As for Tempest and SCAF, they may be
source of the ‘skilled pilots’ capable of cash cows, but you still need to look
‘handling and controlling’ such ‘skittish’ at the future of combat aircraft, and
flying machines – all bringing back if we don’t start investing into future
memories of similar ideas in ‘Popular technologies but the likes of Russia and
Mechanics’ in the 1950s. China do, we could be in trouble.
But at least the FAA is about to issue Alan Warnes
specific requirements that may, we hope, Group editor at large,
bring some sense to the matter. Modern Military
On the subject of the rush to order from
the ‘sketch pad’, we hear of the order
for 555 of Hill Helicopter’s HX50 and its
Dawn of a new era
manufacturer’s claim to industrialise the With reference to your June/July article
helicopter – whatever that means. If it was ‘Dawn of a new era’, the UK/BAE effort
all that easy, I think the well-established should be smoother running than the
helicopter makers would have already done European ‘zoo’. Consider [Dassault
it – but one must wish them all good luck! Aviation’s chairman and CEO] Éric
And finally, the one subject that is really Trappier’s quote on page 41, and the
scary, considering the closeness we are caption on page 37. The NH90 troubles
to an escalating war with Russia, is the should hint at the future of the European
extremely long time being quoted for sixth- effort. All involved should read the last
generation fighter programmes. I cannot three paragraphs on page 35.
help but think in terms of other military Larry Violette
programmes. To again quote your article By email

Get in touch at airinternational@

keypublishing.com and start the
The Russian Ministry of Defence’s first Orion MALE system Key Publishing subject line with Checking In.

October 2022 AIR International 23

 Leading the
charge
Dutch developer Maeve Aerospace
is working on a zero-emissions
electric passenger aircraft. Mark
Broadbent heard more from its
CEO, Jan Willem Heinen

A game-changer

A
ccording to Jan Willem in June 2021, followed by €3.4m in
Heinen, co-founder and funding from a number of unnamed An especially high-profile aspect of
CEO of the Dutch start-up angel investors and a “large Dutch family electric aviation in the past couple of
Maeve Aerospace, every office”, the company was rebranded as years is advanced air mobility and its
form of transport will be Maeve in June 2022. nascent small electric vertical take-off
electrified at some point A statement said: “Maeve will further and landing systems, widely dubbed as
in the future. “It’s not a develop the core technology behind air taxis. Investors have put in billions of
question of if it’s going to be transformed, electric flying, such as the battery system. dollars and hundreds of orders, albeit
it’s when,” he told AIR International. The company is now expanding its provisional, have been placed.
Delft-based Maeve is working on team to 24 employees and is looking at There is plenty of other activity involving
a design for a fully electric regional future locations to further support the electric aircraft or hybrid designs that
passenger aircraft, the Maeve 01, which development of its first aircraft.” combine either conventional and electric
will generate no carbon dioxide or nitrous Maeve’s co-founder and chief operating propulsion or hydrogen and electric
oxide emissions, produce 40% less noise officer Joost Dieben commented: “The technologies. These include initiatives
than current regional aircraft and offer time of planning is behind us. We are from ZeroAvia, Rolls-Royce, Britten
cheaper operating costs. now progressing in development of Norman (which under Project Fresson
Maeve’s origins go back to September the core technology needed in any is electrifying one of its Islanders) and
2020, when the company began life as future electric aircraft – a portable, MagniX (whose electric engines will
Venturi and its engineers embarked on an lightweight and safe battery pack. With power Harbour Air de Havilland Beavers).
extensive electric aviation feasibility study. this technology and IP, we will be able to Start-ups Dante Aerospace and Heart
After closing a €250,000 seed investment make an impact in aviation.” are also planning electric commuter

24 October 2022 AIR International

 Maeve Aerospace wants to
build a 44-seater for regional routes
All images Maeve Aerospace unless stated
aircraft with around 20 seats. While
these developments are centred on Maeve says its aircraft will have a 550km range while
emitting no CO2 or nitrous oxides
relatively small aircraft, or even just the
technologies that will be implemented
in future designs, Maeve Aerospace has
altogether larger ambitions.
Heinen told AIR International: “We are
designing a large-scale all-electric aircraft
and all the technology it requires. We
want to build a pressurised aircraft able to
operate at multiple flight altitudes and
a charging network.
“It’s a gamechanger. You are not
emitting CO2 or nitrous oxide, you’re 40%
quieter than a new aircraft. The reason
is the cost per seat kilometre. Electric
aircraft have unmatched efficiency.
Hydrogen aircraft, ‘well to wing’ [ie, total
lifecycle costs], are 25% more efficient,
but electric aircraft are somewhere
between 75 and 80% efficient.”

October 2022 AIR International 25

 Charging future electric
aircraft will be a key part of
normalising their operations

The Maeve 01 will have 44 seats plus a 30-passenger aircraft and then your IT electric aircraft. Heinen explained: “If
crew and up to 550km range. It will cruise programme would design 30 seats and you’re talking about energy density,
at 264kts, take off in 1,500m and climb at the volume and the weight, then start it’s always useful to dissect two
1,800ft/min. Its planned maximum take- calculating how much wing is required, parameters: cell energy density and
off weight is 45,000kg and its payload what kind of flaps, what kind of battery. system energy density.”
capacity is 4,965kg. That’s what we’ve been doing for the One particular cell design may offer
A parametric design philosophy was past year, and that’s why we’re so sure superior energy density, but Heinen
used to create the Maeve 01, Heinen said: of our parameters. We took everything said: “You might have a less energy-
“In an aircraft, everything is related to into account to a very high-fidelity level. dense cell that has better explosive
everything. The way your wing is shaped We were able to evaluate thousands of behaviour, which equates to a better
or where your battery is [positioned] different aircraft designs – we just put system energy density.”
influences your centre of gravity, and different parameters in the framework and The CEO added that Maeve’s studies
where your CofG [centre of gravity] is 45 minutes later you have a different aircraft indicate that battery power from
[located] influences your fuselage. Every design. That really helped us because we 300kWh to 400kWh per kilogramme
design decision you make influences the wanted to explore different things.” is “really when it starts to make sense
design of the rest.” to fly electric. At 400kWh energy
Today’s IT design programmes enable Energy density density at a system level we can fly
developers to parametrise their work: There is a sweet spot in how powerful 550km with 44 passengers. That’s
“You say, ‘today I would like to calculate batteries must be to power a fairly large a serious mission.”

Electric dreams
Announcements continue to be made about the Adam Goldstein described the deposit as a sign of
emerging electric aircraft systems that promise new confidence in the company’s ability to successfully
forms of air mobility for passengers and cargo. bring Midnight to market.
The electric vertical take-off and landing (eVTOL) “We recently completed the preliminary design
aircraft developer Volocopter flew its first fixed- review for Midnight and are now advancing
winged passenger aircraft, the VoloConnect, back to the next stage of its development and
in May 2022. The company promises a 155mph top commercialisation,” he stated.
speed and 60-mile range on the three-seat aircraft. August 2022 also saw Bristow Group take another
Volocopter said: “With the VoloCity and VoloConnect foray into advanced air mobility with a firm order
air taxi designs fulfilling demands for metropolitan for five of Beta Technologies’ Alia 250 eVTOL
flights and suburban connections in densely aircraft, with the option to purchase an additional
populated regions respectively, Volocopter is ready to 50 units. Bristow Group earlier announced separate
serve a broader range of passengers’ flight needs.” agreements with Lilium for 50 Lilium Jets for
It plans to launch VoloCity commercial services in operations in Florida and other future US and
2024 and VoloConnect services two years later. European markets, and with Elroy Air for up to 100
The US developer Archer announced in August Chapparal hybrid-electric eVTOLs to transport cargo.
2022 that it had received a $10m pre-delivery UK developer Vertical Aerospace announced it
payment from United Airlines for 100 examples intended to begin flight testing its VX4 production
of Midnight, its initial production eVTOL aircraft. eVTOL in late summer from a UK airfield. The VX4
This payment represents a watershed moment not will also feature in a trial involving airlines and
Maeve 01’s planned maximum take-off weight is
just for Archer, but for the broader eVTOL industry. airports in the UK to demonstrate the feasibility of 45,000kg and its payload capacity is 4,965kg
Believed to be the first of its kind, Archer CEO advanced air mobility.

26 October 2022 AIR International

 The Maeve 01’s batteries will have a 400kWh per kilogram energy density

Improving energy densities in batteries means aircraft can fly further or carry more
Getting more power for the same
volume of batteries means that an
aircraft will be able to fly further or
alternatively carry a higher payload.
Heinen said: “There are three energy
densities to consider at this point. One,
the energy densities of batteries that are
right here, right now. There’s the energy
density at which we intend to launch our
aircraft, then the energy density that’s in
2025 and in 2040.
“At launch we will be quite small in
volume, but consider what happens
when our company scales up and
delivers 20-30 aircraft per year and the
energy density in 2023 is 450kWh at
a system level. That’s when you start
making an impact and you start going
for 60 passengers and 1,000km.”
Maeve Aerospace, formerly Venturi, is based in Delft in the Netherlands

“Hydrogen aircraft, ‘well to wing’, are

25% more efficient, electric aircraft
are somewhere between 75 and
80% efficient”

October 2022 AIR International 27

 Bristow Group has signed for BETA
Technologies’ Alia 250 eVTOL Bristow Group

Battery evolution pointed out: “There’s no liquid electrolytes groundbreaking. It’s a prerequisite. If
Various factors can influence energy in the battery, so it’s a safer cell. It’s people buy a €100,000 electric car and
density. There needs to be an efficient flame-retardant, so the packaging around you can’t drive from, say, Germany to the
form factor to minimise the cell the cell will go down.” south of France, it’s a toy. Once you can
‘packaging’ required to protect against Several technologies can be combined, drive [that distance], it’s no longer a toy.
thermal runaway and incorporate the he noted: “Solid state can be combined The same is true for aircraft. If you want
systems necessary for cooling and data with a large cylindrical battery. You can to have [electric] aircraft in the air, you
connections, including a direct-current have solid state with a silicon anode. All of need to have charging.”
bus. However, more packaging means them increase energy density. We are quite Maeve Aerospace intends to use
more weight, which impedes performance. bullish that when we launch, we’ll meet 300- infrastructure that will power-up its
Heinen said he thinks the industry “is 400kWh per kilogramme at a system level.” aircraft in as little as 35 minutes. Running
converging to larger cylindrical cells as the on 100% sustainable energy at a low
most efficient form factor.” Robotised charging price per kWh, Maeve says its ReCharge
Lithium-ion batteries now have higher Of course, batteries are not the system will enable “airlines to focus on
silicone loading on the anode. “We have only consideration for electric their core expertise: flying.”
batteries in our lab that are at 350kwH/ aircraft. Crucially there must also be Heinen explained: “As Maeve 01 arrives
kg, and heading to 400kwH/kg,” Heinen infrastructure to ensure they can operate at its destination, robotised charging
said. “Within two years that’s going to be as intended to perform the bread-and- starts instantly. Integrated into a single
on the road. Going beyond that you’re butter services in an operator’s network. module. A Maeve fast-charging system
looking at solid state batteries, slated Heinen draws a comparison with requires no more than the footprint of
to be launched after 2025.” Solid state Tesla’s electric vehicles: “Ultimately, what a 30ft container.
batteries do not in themselves provide was introduced was a global charging “Maeve 01 charges with up to 9MW
greater energy density, but as Heinen network for electric cars, which was of power. Grid overload is prevented

Lilium is developing a jet-powered electric vertical take-off and landing aircraft Bristow Group Vertical Aerospace’s VX4, due to fly in summer 2022,
will be used in demo flights in the UK Vertical Aerospace

28 October 2022 AIR International

 Volocopter’s latest aircraft,
the VoloConnect, took flight
in May 2022 Volocopter

United Airlines has ordered Archer’s

in-development Midnight eVTOL Archer

because reused Maeve 01 battery developing our concept so we have electrically-powered passenger aircraft
modules assist in providing power. something to show them. We believe at operations an everyday reality. And
Whenever charging is done, our the end of this year we’ll be ready for our looking at the sustainability issue more
ReCharging network will automatically first talks with EASA.” widely, Heinen feels the aerospace
re-energise with 100% sustainable He continued: “We know what we have industry could – and should – be doing
energy at the lowest cost point.” to achieve. At any given point during your much better than it is at the moment:
Heinen stressed that Maeve’s absolute mission any of your batteries could catch “You’ll see that they dance around
first priority is its aircraft and battery fire and you will have to isolate thermal the issue. If you want to be a 100%
system, but he added: “We wanted to runaway and make sure the aircraft sustainable airline you need sustainable
show the power of technology and have functions as intended. That’s quite a aircraft. If you want that, then you need
people imagine the possibility of having a hefty requirement. to order those aircraft.
global coverage of charging networks for “Electric cars are designed to have “What you see in aviation is ‘Yeah, we
electric aircraft. It’s definitely possible.” a thermal runaway and isolate the fire tried to reduce the weight of the cart that
Maeve will have a ReCharge network for two minutes, that’s the automotive carries our food.’ Airlines need to focus
prototype ready in 2023, he added. requirement. For [the aviation industry] on purchasing zero-emissions aircraft.
we have to isolate a thermal runaway They require years and years of focus,
A hefty requirement indefinitely and so you start segmentising dedication, capital and talent.
Certification is inextricably linked into all your battery system into different and “We are actively already working with
aspects of developing electric aircraft and smaller packages.” several airlines, and we are encouraging
the infrastructure needed for their operations. airlines to contact us and work with us.
Heinen said: “We know what EASA “They need aircraft” We need customers, and they need
[European Union Aviation Safety Agency] Inevitably, this means that a great deal zero-emissions aircraft. It starts with
requires from us but we are firstly of work will be required to make market demand.”

“They dance around the issue. If you

want to be a 100% sustainable airline
you need sustainable aircraft”
October 2022 AIR International 29
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 -
The RAF’s

E7 Wedgetail programme
32 October 2022 AIR International
 An artist’s impression of the RAF Wedgetail airborne early warning
paint scheme flying over Kilt Rock and Mealt Falls in Scotland. The fleet
of three Wedgetails will be based at RAF Lossiemouth All images Boeing

Joe Campion provides insight into

the RAF’s latest airborne early warning
programme, the Boeing E-7 Wedegtail
n 2019, the UK MOD announced that equipment plan, the government forecast One’, arrived in Birmingham on January

I
it would be replacing its ageing fleet of that the cost had increased to £2.16bn, 6, while another airframe landed the
Boeing E-3D Sentry AWACS aircraft partly due to training and support costs, following September the same year.
with a Boeing 737 military derivative, including the purchase of new simulators ‘Aircraft Two’ was a second-hand airframe
the E-7 Wedgetail AEW1 airborne and facilities. of a 2011-built 737-73W Boeing business
early warning and control (AEW&C) The Boeing 737 airframes for Wedgetail jet, registration N947BC (c/n 40117, ex
aircraft. The first Wedgetail is due for conversion began arriving in the UK 2-BASG, VP-BOP and N449BJ), and
delivery to the RAF in 2023, but already in January 2021 for modifications was transported from San Bernadino
the programme has hit complications. by Boeing’s partner within the E-7 International Airport, California, via Bangor
The size of the new fleet has been programme, STS Aerospace, based at International Airport in Maine, using
reduced and the RAF’s intelligence, Birmingham International Airport. The callsign ‘BOE130’.
surveillance and reconnaissance (ISR) STS partnership had been set up rapidly The last of the three Boeing 737s
force has switched location. using previous knowhow that had been touched down on UK soil on July 14,
In the initial announcement, Boeing established by Boeing in Australia, which 2022. Known as ‘Aircraft Three’, serial
and the RAF signed a £1.5bn contract already operates the E-7. Registration N576JK (c/n 66840/9105) flew from
for five aircraft, but in the 2019 defence N946BC (c/n 38633), known as ‘Aircraft Boeing’s factory in Seattle.

October 2022 AIR International 33

 A sensor not a radar assistant chief of staff for capability miles of new wiring to the standard 737
The modification of the 737 to the E-7 ISR with the RAF, explained to AIR commercial aircraft to make it capable of
Wedgetail configuration includes the International that the MESA sensor is carrying the military software.
complex fitting of the top-of-the-range far more than just a radar and provides ‘Aircraft One’ in the production line at
Northrop Grumman MESA (Multi-role increased capabilities to the RAF’s ISR STS, which is the furthest along in its
Electronically Scanned Array) sensor, force, hence its dubbing as a sensor. modification process, has undergone
currently being tested and developed in It is a long and complex process to 100,000 labour hours so far and the Mesa
Maryland in the US. fit the new sensor. For a start, section sensor has still not been installed – the
As Northrop produced the MESA system 46 (part of the mid fuselage) of the 737 sensor is actually still in the US, although
for E-7s purchased more than 10 years must be removed and strengthened it is soon to be heading to the UK by sea.
ago, the sensors that the RAF Wedgetails by a team of Boeing and STS staff. To Nevertheless, the RAF and Boeing have
will receive are an updated version of carry out the task, engineers must go said that they are extremely pleased with
those fitted to the Royal Australian Air through an additional eight-week course STS’s performance and progress so far.
Force and Turkish Air Force E-7 fleets. to be capable of carrying out the E-7
At this year’s Royal International Air modification. This includes learning how Fleet reduction
Tattoo (RIAT) in July, Air Cdre Alex Hicks, to fit 1000 more wire harnesses and 116 The original Wedgetail contract was

CLOCKWISE FROM TOP LEFT:

Digital rendering of the new Wedgetail airborne
early warning livery RAF/ Boeing

Aircraft Three being towed into the STS

Aerospace hangar at Birmingham International
Airport after its arrival from Boeing in Seattle

STS personnel strengthening the fuselage of the

Boeing 737 as part of the Wedgetail conversion

A 737 undergoes major modifications in the STS

hangar including fitting 161 miles of wiring

The third and final Boeing 737 for Wedgetail

conversion arriving in the UK in July 2022

34 October 2022 AIR International

understood to have been for five aircraft,
but Air Cdre Hicks said that the decision
to shrink the fleet to three aircraft had
been made by the UK government, not by
the RAF. However, he stressed that three
E-7s would still provide excellent capability
for the UK and its partners.
At the same time, the decision was
made to move the AWACS capability
from RAF Waddington in Lincolnshire
to RAF Lossiemouth in Scotland. This
makes great sense due to the fleet
of P-8 Poseidons operating from the
base and the fact that there has been
a major increase in facilities to service
737 airframes at the base. This includes
the Atlantic Building, which incorprates
a three-bay hangar, accommodation for
squadron members, training and support
activities and flight simulators. The state-
of-the-art £360m facility was procured
and delivered by DE&S.
The location of RAF Lossiemouth on
the North Sea coast makes it the most
strategic location for both the P-8 and E-7
programmes. The combination of having
both aircraft as 737 airframes will reduce
workload and through-life costs.

Future expansion
The RAF is also planning to expand the
E-7 capability into the wider NATO force.
There are ongoing discussions with the
US Air Force (USAF) over its timings to
procure the Wedgetail for its AWACS
capability. USAF aircrew will be part of the
development test and evaluation (DOT&E)
and initial operational test and evaluation
(IOT&E) of the RAF E-7 fleet.
The E-7 is scheduled to go into service
in 2024, but it remains unclear if this
is achievable due to potential teething
problems with the new systems onboard
the aircraft. An initial operational capability
date remains uncertain, as does a full
operational capability date, but the
projected service life for the Wedgetail
will see it out until 2042.
It’s possible this could leave the UK
government in the somewhat unusual
position of looking for an eventual
replacement for the E-7 programme
before the aircraft is fully operational.

Seedcorn programme down under

As the E-7 Wedgetail is already operational
with the Royal Australian Air Force (RAAF),
the RAF currently has a seedcorn programme
taking place in Australia to allow 40 of its
personnel to receive training and hands-on
experience of flying the aircarft and working
with the advanced software. The first team
to undergo training are now back in the
UK and are ready to perform development
test and evaluation (DOT&E) and initial
operational test and evaluation (IOT&E)
when the in-service date of the E-7 arrives .
This is scheduled to be in 2024, but will be
dependent on the aircraft having completed
the modification process at STS Aerospace.

October 2022 AIR International 35

Small
but perfectly formed
Craig West investigates Europe’s ‘mini airliner’ sector and finds out how three
manufacturers aim to remain competitive in an increasingly congested market

36 October 2022 AIR International

T
he ‘heavy metal’ scene The design features a light alloy freighter, air ambulance, search and
may be dominated by monocoque construction, a box-like rescue, oil pollution detection and
global powerhouses Airbus fuselage, and an unbraced high wing, under maritime patrol. The type has received
and Boeing but, at the which hung its two 210hp Rolls-Royce some 2,050 modifications during that
other end of the spectrum, Continental IO-360B piston engines (later time, ranging from snow skis to satellite
the sub-15-seat sector is upgraded to more-powerful 260hp Lycoming communications, and from ducted fan
awash with competing O-540-E4s). It also has a sturdy fixed and turboprop engines to large, nose-
designs from a variety of manufacturers undercarriage (including twin-wheel main mounted radar installations.
on both sides of the Atlantic. gears), large electrically driven one-piece Speaking exclusively to AIR International,
European offerings in this category slotted flaps and manual flying controls. Britten-Norman’s business development
include the veteran Britten-Norman director Lara Harrison revealed: “The
Islander, the sleek Pilatus PC-12 and Great Britten secret of the Islander’s success is the
new kid on the block, the Tecnam The Islander quickly demonstrated its simplicity of its construction, maintenance
P2012 Traveller. These aircraft share impressive capabilities. Its low wing and operation combined with a genuine
similar traits – all three are rugged loading meant it could carry considerably rough terrain, STOL capability. This
utility types with excellent short take- heavier payloads than comparable types makes the aircraft a reliable workhorse on
off and landing (STOL) performance in its weight, power or cost classes. which the remote communities it serves
and the ability to operate from remote, It also has excellent short-field can depend.”
unprepared airstrips with minimal performance – in 1968, it successfully Tellingly, the three most recent orders
infrastructure. But this is where the landed and took off from the aircraft for the type were from the Islands
similarities end. carrier HMS Hermes without the use of Development Company of the Seychelles,
One of the pioneers of this sector arresting cable or catapult. Island Airways in the United States and
is the venerable BN-2 Islander. The The BN-2 is remarkably versatile. With the Falkland Islands Government Aviation
aircraft made its maiden flight in almost 1,300 examples built to date, the Service (FIGAS).
1965 and remains in production today – Islander has found use with operators “Britten-Norman is always seeking to
that it has changed very little, externally in more than 100 countries around the expand markets, as evidenced by our
at least, in almost six decades is world – from Shetland to the Falklands recent release of a high-capacity spray
testament to its remarkable design. – in a variety of roles, including airliner, aircraft. The majority of our expansion

CLOCKWISE FROM MAIN IMAGE:

The Falkland Islands Government Air Service
is a repeat customer for the Islander, receiving
its latest example last year and due to accept
another by the end of 2022
AirTeamImages.com/ Daniel Nicholson

More than 2,000 modifications have been made

to the Britten-Norman BN-2 Islander since its
first flight in 1965 Key Collection

Cranfield Aeronautical Solutions has recently

acquired a former Isles of Scilly Skybus BN-2
Islander for use in Project Fresson
AirTeamImages.com/ Simon Willson

October 2022 AIR International 37

 comes from working closely with other
original equipment manufacturers [OEMs]
to deliver new capability to market,”
Harrison said. “Nonetheless, a hugely
important part of our market is returning
customers. The capability of the product
leaves it unmatched within its particular
niche, which is passenger operations
to remote, rough terrain locations with
landing strips up to 400m [1,300ft].
However, the durability of the design
means that many operators continue to
own and operate their aircraft decades
after initial purchase.”

Keeping ’em flying

Most Islander operators are, according team, we also provide field service have also commenced a trial of our Parts
to Harrison, “self-sufficient and hugely support across the globe, training at Plus service that allows priority access to
resourceful”. Nevertheless, Britten- either the customer’s location or at our parts inventory.”
Norman provides a range of technical and the factory, and a dedicated regional The remarketing of refurbished, pre-
parts services aimed at providing quality customer care team that can help with owned aircraft has also become a key
support to its customers. parts provision, warranty management, aspect of Britten-Norman’s business,
“In addition to a dedicated technical repairs, exchanges and AOG [aircraft on alongside selling new-build examples.
support cell within the design engineering ground] services,” Harrison said. “We “Progressive alterations and repairs can
add weight to ageing aircraft, so many
of our operators prefer progressive fleet
renewals, phasing out older examples
after 10-15 years. These aircraft then
form part of a healthy pre-owned market
that we actively engage in through our
refurbishment programme,” Harrison said.
The overhaul process for pre-owned
Islanders is extensive. “Before we
commence refurbishment, we start with
a full nose-to-tail survey of the aircraft.
We pay particular attention to any repair
schemes that have been conducted by
third parties, and ensure the aircraft is
corrosion free. Our Part M organisation
also does a complete review of the
technical records, to confirm the status
of the aircraft and to highlight any issues
that may have arisen during its service
life,” she explained.
“The aircraft then enters our MRO
facility, where our dedicated team carries
out maintenance and repair activities,
including corrosion rectification and
removal of unapproved modifications,
Launched in 2019, the Pilatus PC-12 NGX is equipped with the in-house developed Advanced Cockpit and then configures the aircraft to the
Environment (ACE) avionics system, which features four 10in LCD displays Pilatus customer specification.

38 October 2022 AIR International

CLOCKWISE FROM TOP LEFT:
Many of the PC-12’s most popular elements have
been applied to the PC-24 business jet, including its
unsealed-strip capability Pilatus

Australia’s Royal Flying Doctor Service was the

launch customer for the Pilatus PC-12, receiving its
maiden example in 1994 Pilatus

The Pilatus PC-12 was originally designed for short-

field operations and unpaved runways, despite its
popularity among the business aviation community
Pilatus

Since May 2016, Okavango Air Rescue has relied on

a single PC-12 for its operations in Botswana and
across southern Africa Pilatus

“Aircraft will also have a [control] panel useful complementary characteristics. equipped with the optional Model250
refit as well as a full cabin review. They Safe low-speed operation and twin- turboprop from Rolls-Royce.
will also normally have an exterior refinish. engine configuration on a high wing, “Our next innovation will be the
“In the last year, we successfully utility fuselage makes the Islander introduction of an electric powerplant,
delivered three aircraft. A fully-refurbished equally §suited to other specialist roles, most likely centred around hydrogen fuel
Islander was delivered to the US and such as urban or coastal surveillance or cell technology.
another to Croatia. We also delivered intelligence gathering, maritime search ”We are engaged in a programme to
a new-build example to the Falklands. and rescue, pollution control or crop modify an Islander and will use the results
The period also saw the order of three spraying. The reconfigurable cabin also of this to define the future production
additional aircraft, due to be delivered provides opportunities for rapid role configuration option, noting that we
by Q4 2022, and we are in final stages change to cargo or medevac operations. regard retaining current passenger and
of negotiation for two more, also to be Consequently, the vast majority of the STOL operation as being fundamental to
delivered this financial year.” changes relate to the wide array of the future of the Islander.
functions that the aircraft can perform.” “At the same time, we are working on an
Moving with the times That’s not to say the Islander hasn’t exciting trials programme, which is looking
Despite its advancing years and benefitted from a multitude of upgrades. at the future of autonomous flight.”
competing designs jostling for the same Outwardly at least, the latest series,
market space, the Islander remains very BN-2B, bears more than a passing Swiss bliss
much in demand. Harrison said: “The resemblance to the first prototype, but The Islander was created to serve in the
most important consideration when it has evolved significantly ‘under the harshest and most remote corners of the
assessing upgrades for the Islander is bonnet’. “We continue to refine the world. However, the Swiss Pilatus PC-12
that the basic design has remained largely internal environment within the aircraft. offers a very different, and arguably
unchanged since inception. The Islander Most recently, we have upgraded the more aesthetically elegant, solution to the
is a classic argument for the old adage ‘if cockpit to Garmin G600Txi IFR suite with same problem.
it isn’t broke, don’t fix it’. full electronic flight bag option. We have The long-established, Stans-based
“What has changed, however, is the also started changes to the cabin interior, manufacturer has great pedigree when it
utilisation of the type. We recognised a to improve the range of options available. comes to utility transports. The successful
design that is suited to its original STOL, “Our core powerplant is the I/O-540 PC-6 Porter and Turbo Porter family
commuter application has many other range, with around 20% of all aircraft is renowned for its sparkling STOL

“The PC-12 offers a unique combination of flying

economically while also enjoying the advantages of
a big, beautifully designed cabin” Jörg Ruckstuhl, Pilatus

October 2022 AIR International 39

 performance – able to take off in less than sleek design that belies its impressive flat floor and convenient airstair ahead of
656ft and land in just 426ft from almost ‘off-road’ capability – a low-wing, T-tailed the wing, the versatile PC-12 is suitable
any surface, while carrying a 2,650lb monoplane with a pressurised cabin, for a variety of roles, from corporate air
payload. It holds the world record for the performance-enhancing winglets and taxi and mini airliner to medevac and
highest landing conducted by a fixed- retractable undercarriage. However, a paramilitary special operations platform.
wing aircraft, 18,865ft above sea level on closer look reveals oversized tyres and Now more than 30 years since its
Nepal’s Dhaulagiri glacier. rugged trailing link gear that soaks up first flight, and with more than 1,800
The PC-12 is an entirely different beast. even the harshest of unpaved runway examples built to date, Pilatus’ director
Launched in 1989, it was aimed at the surfaces, and powerful fowler flaps that of sales and marketing Jörg Ruckstuhl
corporate market, offering a comparable stretch over 70% of its wingspan and shared the secrets behind the aircraft’s
cabin size to the Beechcraft King Air 200 reduce the stall speed to just 67kts. success: “The PC-12 offers a unique
but with single-engine economy. It’s a Combined with the large rear cargo door, combination of flying economically, due to
its single engine, while also enjoying the
advantages of a big, beautifully designed
cabin. This is why it has proven itself as
the most versatile and valued business
aircraft in the world.”

Better than ever

The Pilatus has received a variety of
enhancements since entering service
with launch customer the Royal Flying
Doctor Service of Australia in 1994 (see
State of emergency, AIR International
September 2022)232w . The PC-12
NG (next generation) was unveiled in
2006 and introduced a more-powerful
Pratt & Whitney PT6A-67P engine and
new winglets (leading to better climb
performance and higher cruise speed),
together with upgraded cockpit avionics.
The latest iteration, the third-generation
PC-12 NGX, followed in 2019 and is,
according to Pilatus, the ‘world’s best
turboprop’. Ruckstuhl explained: “This
upgrade has taken the aircraft to the
next level of refinement, efficiency
and technological advancement. The
introduction of autothrottle, tactile
feedback [which bumps the yoke to alert
the pilot if the aircraft adopts an unusual
attitude], electronic propeller and engine
control system, plus industry-leading
features enhancing safety and situational
awareness, all work together to further
help PC-12 NGX operators fly safely and
efficiently. In addition, passengers enjoy
new executive seats, more headroom,
larger cabin windows and modern BMW
Designworks interiors.”

40 October 2022 AIR International

 At the heart of the NGX is the P&W fleet of Pilatus turboprops with an
PT6E-67XP, which produces 1,200shp order for 20 third-generation examples
and is the first turboprop powerplant in last March.
general aviation to offer a dual-channel What does the future hold for the
integrated electronic propeller and PC-12? Pilatus delivered 88 NGXs last
engine control system. When married year and has a strong order backlog
with Honeywell’s Advanced Cockpit – Tradewind is planning to receive its
Environment (ACE) avionics system, first example during the third quarter of
it significantly reduces pilot workload. 2022 and expects deliveries to continue
The new cabin now features the larger over the next five years. An increasing
rectangular windows of the PC-24, and number of operators are using the type
customers can select from six different commercially, connecting niche markets,
BMW Designworks interiors. complementing mainline carriers on low-
Notably, the NGX does not just deliver traffic, hub-and-spoke routes, or serving
improvements for pilot and passenger, fixed-fee membership or fractional-
but also for operators. Scheduled ownership customers.
maintenance intervals have been Despite this success, Pilatus is not
extended to 600 flight hours and the time resting on its laurels.
between overhauls has increased from “Since we started deliveries in 1994,
4,000 to 5,000 hours, making the aircraft Pilatus has continually improved the
more affordable to fly. PC-12. We listen to our customers and
their input is taken into account when CLOCKWISE FROM THIS IMAGE:
Norwegian regional specialist Widerøe has entered
The power of the network elaborating new ideas,” Ruckstuhl said.
an agreement with Tecnam and Rolls-Royce for an
The global PC-12 fleet has now amassed “Obviously, we are also closely following electrically powered version of the P2012 marketed
more than eight million flight hours any developments in the industry, in as the P-Volt
of operating experience, hundreds order to make sure that the name Pilatus Tecnam
of thousands of which were accrued continues to stand for innovation and
in some of the world’s harshest quality in aircraft construction.” Cape Air – the global launch operator for the Tecnam
P2012 Traveller – now fields more than 24 examples
environments. To keep these aircraft
of the Italian-designed and built twin
flying, Pilatus has built up a dense New kid on the block Kas van Zonneveld
worldwide network of authorised On paper at least, the decision to enter
service centres. what is already a congested and highly Tecnam offers the P2012 in a range of
This multi-award-winning service is a key competitive ‘mini airliner’ market makes configurations, including an 11-seat passenger
reason many of the Swiss manufacturer’s little sense, and yet that’s exactly what airliner, medical evacuation, freighter and special
more-recent sales are to existing PC-12 Tecnam did in 2011 when it formally mission platform
Tecnam
operators – the first NGX to be delivered launched its P2012 Traveller.
replaced a US customer’s PC-12 The Italian company was created in 1986 Zil Air received a pair of Tecnam P2012 Travellers,
NG, while Caribbean regional carrier by the Pascale brothers Luigi ‘Gino’ and S7-EVE and S7-ADM, in 2019
Tradewind Aviation bolstered its 18-strong Giovanni ‘Ninò’, renowned aeronautical AirTeamImages.com/Markus Mainka

October 2022 AIR International 41

 “The secret of the Islander’s success is the
simplicity of its construction, maintenance and
operation combined with a genuine rough terrain,
STOL capability” Lara Harrison, Britten-Norman

The Britten-Norman BN-2 Islander’s

appeal continues to endure six decades
after the type’s first flight Key Collection

engineers of Partenavia fame. It was is optimised to reduce workload in all Most recently, Tecnam secured a deal
originally intended to produce components weathers. At its heart is the Garmin from New Mexico-based flight school
for other manufacturers but, pushed by G1000NXi suite, which, when twinned Bellator Aviation for its first P2012,
CEO and nephew Paulo, quickly turned to with a GFC700 autopilot, provides for a which it will use to launch passenger
designing and building its own range of high degree of automation. The engines services from its Las Cruces home to
popular general aviation and light sport are also fully electronically controlled Albuquerque, Santa Fe, Dallas, and
aircraft, all of which bear the ‘P’ prefix, in and fuel injected, allowing for almost Phoenix. This followed an order from
honour of the Pascales. carefree handling. Southern Airways for two aircraft – the
Tecnam’s move into commercial aviation The P2012 can be quickly converted Palm Beach-based operator anticipates
wasn’t entirely of its own volition, but was between commuter, medevac and adding up to four further examples within
instead a rather direct case of responding air cargo roles, and it’s designed for 18 months.
to market demand. Massachusetts-based prolonged, high cycle operations and ease Sales to airline customers outside the
commuted carrier Cape Air was seeking a of maintenance, which reduces downtime US have been decidedly slower so far,
modern replacement for its fleet of Cessna for overhauls. It also doesn’t require a type though the type is now in service in the
402s and after being rebuffed by Cessna rating for pilots, and can be flown under Seychelles with premium ‘aerial limo’
and Piper, it approached Tecnam to develop existing Multi Engine Piston licences. provider Zil Air.
an aircraft that would meet its needs.
It was a significant undertaking, but the Tecnam trials Forging ahead
result is impressive. The Traveller is of Since achieving European Union Aviation For an operator in the market for a sub-15-
comparable size to the Islander (around Safety Agency (EASA) and US Federal seat ‘mini airliner’, there’s plenty of choice.
3ft longer but with a marginally shorter Aviation Administration (FAA) certification The Islander, PC-12 and Traveller may
wingspan) and shares many attributes, in December 2018 and August 2019, boast many of the same attributes, but
including a high wing, twin engines – respectively, the Traveller has racked up each has a unique selling point that keeps
in this case turbocharged Lycoming several orders, particularly in the US. them all – old and new – viable today.
TEO-540s, each producing 375hp – an Unsurprisingly, the aircraft is well With manufacturers across the board
unpressurised all-metal cabin and rugged supported by launch customer Cape Air. taking great leaps in the use of sustainable
fixed undercarriage that enable operation The airline has reaffirmed its commitment fuel, new powerplants – such as electric
from unprepared airstrips. to the P2012, ordering another ten aircraft propulsion – and other innovations in
However, as a clean sheet design, in March 2021 and optioning a further cockpit suites, along with increased
it incorporates many innovations that 20 (ten each for 2022 and 2023). It also automation that maintains or improves
simply aren’t available in older types. reiterated its desire to ultimately operate safety margins, even in extreme conditions,
Up front, the innovative Single Pilot 100 Travellers and replace its entire the outlook for these small but mighty
Advanced Cockpit Environment (SPACE) Legacy fleet. aircraft remains decidedly positive.

42 October 2022 AIR International

 NE
W

THE ENGINE THAT

CHANGED THE WORLD
The invention of the jet engine had a profound effect on the
world. Commercial jet aircraft revolutionised travel, opening
up every corner of the planet. Few know that the jet engine
was invented by an Englishman in 1929. The invention was
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parts with one part: a single smoothly revolving turbine.

Although the world’s first jet airliner was the British de

Havilland Comet, Britain then gave away the technology
– not only to the United States but to the Soviet Union as
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339/22
 R202/64-GB, one of the last two C-160Rs of the EEA
1/54 Dunkerque can be seen during training of the
crew of R212 for the farewell tour on March 9, 2022
in BA105 Évreux

Transalls
take a bo
44 October 2022 AIR International
 With the retirement of the last C-160R,
Babak Taghvaee reviews the history of the
iconic workhorse and the future of French
military transport aircraft

he French Air and Space April 2020. A400Ms of the 61st Transport

T
Force retired its last two Wing logged 4,200 flying hours in 2020,
Transalls from service almost a 50% increase compared with
on May 20 this year, 2,700 hours of flight in 2019.
after a distinguished With the start of the delivery of the
career as one of the A400Ms, more C-160Rs were phased
most successful tactical out. However, due to the delays in the
airlifters in the world. The last operational A400M programme, some of them
French C-160Rs were used for two had their lifetime extended during their
key roles: C-160G Gabriel pilot training overhaul or depot maintenance.
with EEA 01.054 Dunkerque, and The last eight remaining first-generation
Special Operations of the Air Parachute Transalls were retired mid-2017. The
Commandos with ET 03.061 Poitou. last of them, R160, was due to be
handed over to the Transall Generation
Enter the A400M Association to be preserved in flying
Airbus Military SL (an Airbus subsidiary) condition. However, the decision was
and the joint European military changed and it was cannibalised for
procurement agency reached a €20bn spare parts to support the remaining fleet
deal on May 27, 2003, to produce the of 17 airworthy C-160Rs.
Airbus A400M transport aircraft as a Unable to refuel the helicopters, land
successor for the Transall. It was ordered on rough runways and perform tactical
by France, Germany and Turkey, but later landing with the runway run as short as
sold to other countries including Spain, C-160’s, the A400Ms were never suited
Belgium and Luxemburg. for operations of French Special Forces
The A400M’s mass production faced in Africa. This resulted in procurement
delays that subsequently hit delivery of two C-130J-30s and two KC-130Js,
dates for the French Air Force. In 2005, which replaced Transalls in the African
France had 48 C-160A/R (first-generation) theatre from 2020 enabling the Air and
Transalls and 20 C-160R NG (second- Space Force to speed up their retirement.
generation) aircraft still in use of four
transport squadrons. Many neared the The 61st Transport Wing
end of their 20,000-hour service life while In 1967, the Transport Squadron 1/61 (ET

ow
others had to be retired before the start of 1/61) Touraine from the 61st Transport
the delivery of the A400Ms. Wing at Orléans-Bricy was the first unit
The first aircraft, C-160R (R05/61-ME), to be equipped with C-160R. ET 2/61
was retired in 2005. Its airframe was Franche-Comté and ET 3/61 Poitou
delivered to the 1st regiment of the were its other two squadrons receiving
parachute training (1st RTP), at Francazal, C-160Fs as replacement for their Nord
to use for training. N2501 Noratlas transport aircraft.
Between 2006 and 2013, two C-160A In total, 50 first-generation C-160Fs,
(pre-production C-160Fx), 24 C-160Rs together with three C-160A pre-
and one C-160NG were retired. production aircraft, were delivered to
The first A400M (007 manufacture serial three squadrons. A total of 29 C-160NGs
number) was delivered to the French Air were delivered to ET 1/64 Béarn and 2/64
and Space Force on August 2, 2013. Anjou from 64th Transport Wing at Air
Deliveries continued smoothly with Base (BA) 105 Évreux from December
the next five between November 2013 1981 and April 1982, respectively. They
and December 2014, but delays then also replaced Nord N2501s.
began. Airbus Defence was fined over In 1988, the ET 2/61 Franche-Comté
the delays and the excess development had its C-160Fs replaced by Lockheed
costs in 2016. Martin C-130H/H-30 Hercules tactical
Between June 2015 and April 2021, the airlifters. Fourteen C-130s were delivered,
French Air and Space Force received 12 resulting in the withdrawal of the C-160Fs.
more A400Ms. They entered service with Those Transalls were absorbed into two
the transport squadron 1/61 Touraine other squadrons, the ET 1/61 and 2/63.
The diamond formation of the C-160R serialled
R212, together with an A400M, a CN.235M-300 and
(ET 1/61). It was attached to the 61st The first group of the first-generation
a C-130J-30 of the French Air and Space Force Transport Wing on September 1, 2015. Transalls that were retired before 2012
during the retirement ceremony on May 20, 2022 The ET 1/61 received its 17th A400M were mostly from ET 1/61 Touraine. As a
All images Babak Taghvaee (0102 with F-RBAQ civil registration) in result, the squadron was temporarily

October 2022 AIR International 45

 R212/64-GL passing over BA105
Évreux for the last time before official
retirement on May 20, 2022

A number of C-160Rs stored and cannibalised for

their parts in BA123 Orléans-Bricy can be seen in
this image. They will be scrapped in summer 2022

closed in August 2012, but reactivated ET 3/61 were upgraded for the French to be R204; the R203 is also believed to
again in 2014 to fly the A400M. Special Forces. They were also used have gained such capability. In addition,
The C-160NGs were equipped with for C3ISTAR (Command, Control, the ET 3/61 operated R206, R214 and
in-flight refuelling probes, enabling them Communication Intelligence, Surveillance, R226. They were distinguishable from
to receive fuel from the French C-135F Target Acquisition and Reconnaissance) the C-160Rs in use by the 64th Transport
Stratotankers. Among them, 15 aircraft during operations in Africa. Wing by means of their self-protection
were modified to be used as tankers, The C3ISTAR capability was based systems including the sensors for their
capable of refuelling helicopters, fighter on a day/night optronic turret with laser missile approach warning system as well
jets and other C-160F/NGs. designator and image processing console as their chaff/flare dispensers.
They were later serialled R201 to R215 to carry out surveillance, intelligence, Three of the last Transalls from ET
after an upgrade to C-160R standard in targeting and reconnaissance missions. 3/61 Poitou were handed to the Transall
the 1990s. The aircraft was modified to carry a Generation Association in Toulouse after
The ET 3/61 Poitou had three escadrilles forward-looking infrared (FLIR) camera their retirement. The aircraft, R204, R203
(squadrons): F118 ‘Hibou sur un Croissant under its landing gear nacelle that and R226, were flown to Toulouse on
de Lune’, which operated C-130H/ could transmit video and images to a April 28, 2022. R204 is planned to be
H-30s; F119 ‘Chauve-souris sur un command post on the ground using preserved at the garrison of 1st Parachute
Croissant de Lune’, operating C-160Rs; a communication satellite. The ISTAR Train Regiment (1er RTP,) while the other
and F121 ‘Hibou aux Ailes éployées sur capability of the aircraft was tested two will be kept operational.
un Croissant de Lune’, which operated successfully in Africa in 2018. R203/64-GC was the last C-160R of the
the DHC-6-300. Within their final years One of the Transalls modified for French Air and Space Force that passed
of service, the C-160Rs in use by the C3ISTAR capability in ET 3/61 is known a heavy maintenance test at Clermont-

46 October 2022 AIR International

 French Special Forces during training with
R212/64-GL, a Transall of EEA 1/54 that was
borrowed by the ET 3/61 for this purpose

An example of EO/IR (FLIR) surveillance and

targeting cameras that were installed on the
C3ISTAR-capable Transalls of ET 3/61 Poitou

R204/64-GD was in service of ET 3/61 Poitou when it was

Ferrand Aeronautical Industrial Workshop. retired earlier this year. Here it can be seen departing
It was delivered to ET 3/61 after its BA123 Orléans for a training mission of French
overhaul on September 29, 2021. Parachute Forces in September 2019

64th Transport Wing

On August 25, 2017, ET 4/61 Béarn
was temporarily disbanded at BA105
Évreux, leaving some of its aircraft to be
absorbed by ET 2/64 Anjou, while some
others were withdrawn from use to be
cannibalised for parts.
ET 2/64 was disbanded on August 31,
2020, leaving some of its aircraft to be
used by the Airborne Electronic Squadron
(EEA) 1/54 Dunkerque for training of the
last aircrew of the C-160G Gabriel SIGINT
aircraft of the squadron.
Before the temporary disbandment of
ET 2/64 Anjou, one of its C-160Rs (R211,
with 64-GK code) performed a final tour
of a French Transall in Africa, marking

October 2022 AIR International 47

 the end of its 50 years of operations on
the continent.
ET 2/64 Anjou aircraft were absorbed by
the EEA 1/54 Dunkerque in September.
Some remained mission capable in-order
to be shared with ET 3/61 Poitou in
Orléans-Bricy if needed.
They were intended to be used for
Gabriel pilot training at EEA 1/54
Dunkerque, but continued performing,
including supporting overseas operations
in French Polynesia.
A C-160R (R217) that was the last
operational Transall still in its green/grey
camouflage was assigned to ET 0/82
Maine at Tahiti/Faa’a (French Polynesia) in
July 2021.
During its deployment, R217 performed
more than 60 missions across a territory
as large as Europe, including French
Polynesia’s 118 islands and atolls. The
aircraft carried out logistical support,
liaison, medical evacuations and training
missions to keep its crew fully operational.
After eight months in the south-central
Pacific, it returned to Orléans air base
on March 6, 2022. On March 26, it was
retired from service and was flown to the
European Fighter Aviation Museum at
Montélimar to be put on display.

The end of Transall

Major ‘Dahu’, (full name withheld for
security reasons) the head of operations
of 64th Transport Wing, described the
final days of the Transalls in his wing.
He said: “I joined the Évreux Wing [64th
Transport Wing] in 2008. I started flying
R217/64-GQ was deployed to Tahiti in French
with the aircraft from that time until the Polynesia for eight months for the last time until
end of its career [this summer]. I served in February 28, 2022. It is now on display at the
three squadrons here, after disbandment fighter aviation museum at Montélimar
of one and another I finally joined the last
one of them [EEA 1/54 Dunkerque].
“We used the Transalls not just for
Gabriel pilot training, but also operational
missions such as transport and other
missions [medical evacuations, parachute
jumping] – our missions here with the
squadron in Orléans [ET 3/61 Poitou]
were different, however we shared our
aircraft with them.
“I flew with Gabriel for more than 3,000
hours and currently I have a second
licence on Beechcraft [B.350ER VADOR].
“One of my last operational missions
was with R217. During the summer last
year, the aircraft flew to Tahiti to support
missions of the [transport] squadron
there. I spent around one month there
including Christmas. It takes about ten
days to go from France to Tahiti and the
same time to return.
“After that I flew with R212 during the
farewell tour. We still don’t really know
what exactly will happen to R212 [after
retirement], but currently the air and
space force is trying to keep all the
remaining [last retired] aircraft to send
them to museums and also keep some in
airworthy condition.”
On May 20 this year, the C-160R

48 October 2022 AIR International

 Transall was retired at a ceremony that
was attended by General Stéphane Mille,
commander of the French Air and Space
Force, together with other high-ranking
officers.
During the event, the C-160R flew in
a four-ship diamond formation with an
Airbus A400M in special colours of the
ET 4/61 Béarn, a C-130J-30 Super
Hercules of the Franco-German C-130J
Tactical Transport Squadron and a
CN.235M-300 of EC 3/62 Ventoux.
During his speech at the ceremony,
General Hervé Bertrand, Inspector of
the Air and Space Force, told personnel
Major ‘Dahu’ (full name withheld for security assembled: “The first Transall ‘F’ entered
reasons), head of operations, 64th Transport Wing service with the air force on November
22, 1967 and joined the 1/61 Touraine
transport squadron in Orléans. Today,
the end of the intense and glorious
career of the Transall means for many of
you a change of duties.
“Your commitment will continue within a
bold, agile, open and connected air and
space force, which prepares airmen for
today’s combat, and which is mobilised
on the training of tomorrow’s airmen.”
Lieutenant Colonel George (full name
withheld), head of the French Air
and Space Force Approved Training
Organisation (ATO), piloted the R212
during the farewell ceremony.
He said: “I have been a pilot since
Lieutenant Colonel George, head of the French Air 1994 and I have 6,500 flying hours on
Cockpit of the R202/64-GB, one of two and Space Force Approved Training Organisation C-160 [Transall]. I have commanded
last C-160Rs of EEA 1/54 Dunkerque (ATO), piloted the R212 during the farewell airlift groups during the operations
ceremony in May this year
abroad 30 times.
“This is a wonderful aircraft and has
kept its high operational performance
over generations. It can land on every
type of surface – grass, concrete,
unpaved, sand, etc.
“It has a high banking rate which we
demonstrated during the event [the
farewell ceremony]. It has also a high rate
of descent, 6,000ft per minute thanks to
its airbrakes. It is highly manoeuvrable,
capable of pulling 2.5G on clean
configuration thanks to its control and
hydraulic systems and wing design.
“R212 [the C-160R in the farewell
ceremony] was painted in special colours
for its last flights to represent the national
flag. Our last two aircraft including this
will be preserved in the museums.”
Despite the last two airworthy C-160Rs
being retired on May 20, 2022, the final
C-160G Gabriel SIGINT remained in use to
monitor activity of the Russian Navy and
Army by flying near Ukrainian airspace over
Romania. The aircraft played an important
role in collecting information about the
activities of Russian forces in Ukraine for
the French Armed Forces and NATO.
The last C-160G Gabriel was redeployed
back to Evreux on May 31 and was
officially retired on June 20,2022.
The aircraft was flown to Le-Bourget
airport that day and was handed over the
Air and Space Museum where it is planned
to be displayed in near future.

October 2022 AIR International 49

 ollowing a longer-than- urban areas in the coming decade. As with much of the airshow,

F
usual four-year break owing From Boeing-backed venture Wisk, sustainability was a priority, and the
to COVID-19, aerospace whose pilotless ‘Cora’ air taxi made its start-up’s cabin concept incorporates
companies big and small were European debut, to Bristol-based Vertical materials such as advanced recyclable
in a rush to do business at Aerospace, whose impressive eVTOL carbon fibre reinforced thermoplastic,
Farnborough. While the 2022 prototype occupied one corner of the plant-based leather and recycled plastic
Hampshire gathering lacked exhibition space, progress made by the fabric. The seat frame also utilises
the blockbuster orders of previous shows, advanced air mobility sector since 2018 excess raw materials from the airframe
billions of dollars in deals were done and was clear to see. manufacturing process. Embraer’s EVE
fledgling firms were given a platform to Supernal, launched as the urban also unveiled a cabin mock-up at the
debut their products across a range of air mobility division of Hyundai Motor 2022 airshow alongside a new design for
fields, from airport operations to space. Group in 2020, revealed its initial eVTOL the eVTOL that uses a conventional wing
Between the vast halls and plush chalets vehicle cabin concept at Farnborough and tail instead of the previous canard
that made up 100,000m2 of exhibition this year. Supernal is targeting a 2028 configuration. The latest iteration sees
space, it was hard not to be impressed by operational launch of its aircraft and is the eight rotors fixed around the wing,
the displays of new electric vertical take- seeking help from 50 affiliate companies providing vertical take-off and landing
off and landing (eVTOL) aerial vehicles spanning automobiles, automotive parts, capability, and visitors were able to
that developers hope will reshape how construction, robotics and autonomous explore the external features of the aircraft
people travel around and between driving to help it reach that goal. through augmented reality technology.

50 October 2022 AIR International

Bright young
From remote piloting to drones that can take off in Force 10 storm conditions,
things
some of the most innovative technology at Farnborough International Airshow
was the work of start-ups, reports Tom Batchelor

The X-6A Huntress II from WaveAerospace functions

in adverse weather, including Force 10 storm
conditions and ground-level icing WaveAerospace

Also worth noting was the non-binding a commercial aircraft from the runway to the system improves airport safety and
letter of intent between Embraer and BAE a boarding gate without the use of the drastically reduces the risk of collisions with
Systems for the companies to explore the jet’s engines or diesel-powered ground other aircraft and structures. A prototype at
potential order of up to 150 EVE vehicles equipment. After landing, the pilot taxis to Oklahoma’s Ardmore Municipal Airport was
for the defence and security market, a an appropriate taxiway and manoeuvres expected to be operational by the autumn
significant step for the developer. the aircraft nose wheel onto the ATS tow of 2022. Vince Howie, ATS’ CEO, said the
dolly. Once secured, the aircraft’s main jet “current method of moving aircraft with
Aircraft Towing Systems engines are shut down and the aircraft is a tug powered by fossil fuel and several
Among the large North American moved using the ATS underground channel human operators is about as old as human
contingent at Farnborough was Aircraft system to an apron location. The pilot or flight. This age-old method is inefficient and
Towing Systems (ATS), an Oklahoma- ground controller can detach the aircraft unsustainable”, adding that the new system
based company which was showcasing from the ATS in approximately 45 seconds was a “first step” towards an automated
an innovative, and potentially carbon-free, or less, and the pilot can overpower the and integrated ground support network.
alternative to traditional aircraft tugging and ATS system through the use of the aircraft
taxiing methods which it hopes airports brakes or throttles if required. The system Flare Bright
around the world might soon adopt. is estimated to increase airport throughput Flare Bright, an Oxford-headquartered
The system relies on a subterranean by 30% without the need for additional SME numbering just 15 employees, uses
electro-hydraulic-powered pull car and gates, as well as achieving significant machine learning to increase the safety
tow dolly system with the potential to move emissions savings. ATS also says that and performance of drones and wider

October 2022 AIR International 51

 drone infrastructure. The company has
adapted a gliding nano-drone to measure
wind quickly, efficiently and inexpensively,
with each flight taking just ten seconds
and the wind measurements immediately
beamed back to an aircraft to create
live wind maps. Flare Bright recently
won funding from UK Research and
Innovation’s (UKRI) Future Flight Challenge
for two other projects: Sustainable
Aviation Test Environment (SATE) and
SafeZone. Under the SATE banner, Flare
Bright has demonstrated precision flights
of a parcel-sized gliding drone system as
part of a novel remote delivery concept.
The third and latest phase of SATE, which
attracted the UKRI funding, will see Flare
Bright use its ‘machine learning digital
twin ecosystem’ to develop a dedicated
test environment airspace based at
Kirkwall Airport in the Orkney Islands.
Running concurrently, SafeZone aims
to make drone flights safer by creating
a data service that provides real-time
information about aerodynamic hazards in
urban environments. The SafeZone team
is focused on generating and using local
meteorological data to allow unmanned
aerial vehicles (UAVs) to adapt their route
as they fly through wind changes and
close to buildings. Cardiff International
Airport is joining Cranfield University as

52 October 2022 AIR International

 CLOCKWISE FROM TOP LEFT:
Aircraft Towing Systems’ solution features a
subterranean electro-hydraulic-powered pull car and
tow dolly system
ATS

Astroscale’s ELSA-d mission successfully completed

a complex rendezvous operation earlier this year
Astroscale

The Astroscale team performs pre-launch tests at the

Baikonur Cosmodrome in February 2021
Astroscale

A concept image from Flare Bright, one of ten

companies chosen from 150 applicants for the
Boeing-sponsored Aerospace Xelerated programme
this year
Flare Bright

In a first for commercial aviation, Reliable Robotics

remotely piloted an aircraft from a private control
centre last year. Shown here, chief pilot Elissa Zavora
at work
Reliable Robotics

a partner on the project, and will host its Robert Rose, co-founder and CEO, total investments well above the $100m
flight-testing element. added: “We will introduce automation threshold, Reliable Robotics remotely
into the airline operation once we have operated the Cessna 208 Caravan, a
Reliable Robotics proven to ourselves and the FAA that popular cargo aircraft, from a control
Launched in 2017 to expand the reach of these systems can be deployed safely for centre over 50 miles away, again proving
autonomous aircraft, Reliable Robotics commercial use.” the viability of its technology in a real-
is developing a system that will enable The company made history in 2019 by world scenario. In April, the company
the remote operation of any aircraft type remotely piloting a Cessna 172 Skyhawk secured a contract with the Air Force
across all phases of flight, including taxi, over a populated area without crew Research Laboratory (AFRL) to design,
take-off, landing and parking. onboard. Last year, as well as pushing develop and test autonomous aircraft
The Silicon Valley start-up, which
was showing off its technology at
Farnborough, aims to unlock access to
thousands of what it calls “underutilised
regional and municipal airports”, with
licensed pilots required only to supervise
each flight from a remote control centre.
The major benefit is that the system has
the capability to autoland an aircraft at
smaller airstrips in rural or remote areas
without requiring expensive infrastructure
to be installed and maintained, opening
up cargo and other flight services for
hard-to-reach communities.
“We are working with leading cargo
carriers eager to integrate remotely piloted
systems into their fleets,” explained Jeff
Drees, director of cargo strategy for
Reliable Robotics, earlier this year. “By
demonstrating crewed air cargo delivery
first, we will build a solid foundation for
the transition to remotely operated flights.”

October 2022 AIR International 53

 of replica debris – which were launched ACMI / charter services, which will help
into a 550km orbit from the Baikonur with crew training ahead of the scheduled
Cosmodrome in Kazakhstan in March service operation, Saini said.
2021. Lessons learned from ELSA-d
will feed into the ELSA-M project. “The Feel Air Japan
journey to reunite the servicer and client, Feel Air Holdings, Japan’s first regional
along with the successful completion airline franchise, was established as
of switching from absolute to relative recently as June 2022 and scheduled to
navigation, have allowed us to prove even enter into service in the spring of 2024
more key technologies and operational with the Feel Air East brand.
capabilities required for commercial end- The company signed a letter of intent
of-life debris removal services,” said Seita for up to 36 ATR aircraft at the airshow
Iizuka, ELSA-d project manager. “Proving as part of plans to establish new regional
these capabilities gives us, and our connections across the Japanese
partners, greater confidence in our debris archipelago, which has close to 100
capabilities on US Air Force platforms. removal service developments.” airports. Exclusive use of ATR aircraft for
“Our remotely piloted aircraft system its domestic operations will see a fleet
unlocks opportunities for all defence Hans Airways that consists of both ATR 42-600 and
agencies and drives mission success Hans Airways, a new long-haul airline ATR 72-600 aircraft, as well as the short
in cargo delivery, logistics, surveillance, seeking to connect Birmingham, the UK’s take-off and landing variant, the ATR
and other applications where higher second city, with India, marked the arrival 42-600S. “Over the coming years, Feel
tempos and lower costs are vital,” said of its first Airbus A330-200 on UK soil at Air Holdings will establish at least five
David O’Brien, senior vice president of the beginning of August. The airline’s regional airlines, with a fleet that
government solutions at the California- senior management say they have will ultimately comprise 36 ATR
headquartered company. identified a high demand for regular aircraft. Our fundamental goal is
secondary city air links between to improve regional air mobility
Astroscale the UK and India, drawing on its in Japan by connecting
Japanese space specialist Astroscale is CEO’s experience launching a local destinations
developing a range of products, including series of charter flights that currently
in-orbit servicing, in situ space situational for Monarch Airlines
awareness and debris removal. and FlyJet.
The company has ambitious plans to Hans Airways’ CEO
deliver a debris removal service to satellite was in Farnborough
operators and is aiming to launch its to drum up support
End-of-Life Services by Astroscale-Multi for the fledgling carrier,
(ELSA-M) servicer towards the end of whose newly re-registered
2024. Once complete, the servicer will in launch aircraft G-KJAS touched
a single mission be capable of capturing down from Palma Airport, Mallorca,
and removing multiple satellites at the at Birmingham International Airport
end of their operational life in low Earth following a thorough 200-hour
orbit (LEO), helping to address the issue inspection in Abu Dhabi by Etihad
of space congestion and protect services Engineering, which had
such as weather forecasting or GPS that been contracted by its
could be affected by interstellar debris. former airline operator,
Shortly before the airshow, Astroscale Air Europa. Work
announced that its End-of-Life Services undertaken in Palma do not have
by Astroscale-demonstration (ELSA-d) included a final internal air service, thereby
mission had successfully completed inspection of the engines creating stronger
further “controlled close-approach and rectification of defects links between regional
rendezvous operations” between two identified on the airworthiness and businesses and people,
spacecraft in orbit. ELSA-d is the world’s positioning flight. Speaking at the generating new markets,
first commercial mission to prove the airshow, CEO Satnam Singh Saini said and enriching local economies,” said
technologies necessary for on-orbit Amritsar, centre of the Sikh faith, would be Hideki Ide, CEO of Feel Air Holdings.
satellite servicing in LEO. The project the initial destination, with a second A330- The four other airlines under the parent
consists of two satellites – a servicer 200 to be deployed between India and company will be Feel Air West (scheduled
designed to safely remove debris from Toronto, Canada. As Hans Airways finalises to start operations in spring 2026), Feel Air
orbit and a client that serves as a piece slots and timetables, it first plans to operate Central, Feel Air North and Feel Air South.

54 October 2022 AIR International

OPPOSITE; CLOCKWISE FROM TOP LEFT:
Feel Air East brand will use ATR aircraft for
all domestic operations. Its fleet will consist of
ATR 42-600 and ATR 72-600 aircraft, as well as the
ATR 42-600S STOL variant
ATR

New UK long-haul airline Hans Airways took delivery

of its first Airbus A330-200 in early August 2022
Hans Airways

Feel Air Holdings signed a letter of intent for up to

36 ATR aircraft at Farnborough International Airshow
this year
ATR/ Feel Air Holdings

Steelo
Attending Farnborough International
Airshow for the very first time in July,
Steelo demonstrated its modular
fabrication and 3D printing of steel.
Its innovative technology and
manufacturing processes – from modular
fabrication to robotic welding and 3D
printing of steel – have the potential to
“revolutionise” the way that aircraft and
other large-scale objects used in the
industrial sector are manufactured, the
company says. Steelo has partnered with
Cranfield University and Imperial College
London to develop robotic systems for 3D
steel-printing technology through a project A spokesperson for the consortium build aircraft that carry our customer’s
known as High Productivity Wire Arc said: “3D printing has proven numerous critical payloads. What differentiates our
Additive Manufacturing (HPWAAM), which benefits over traditional processes in aircraft from all other small unmanned
brings together terms of speed, design, sustainability aerial systems is that our aircraft can
seven specialist and cost. This research will explore fly 24/7/365 in almost any weather
organisations the next generation of solutions that conditions. In other words, we fly during
and experts in High Productivity Wire Arc Additive the storm when we are needed most –
the energy and Manufacturing can unlock.” not after. Imagine being able to deliver
construction a critical organ for transplant; find a
sectors as well as WaveAerospace lost child at night; mark the location
£1.2m of funding Also attracting attention with its UAV of a sinking ship faster than a full-size
from Innovate prototype drone was WaveAerospace, which helicopter can. That’s what we’re really
UK, which is part used the airshow to introduce its new X-6A here to showcase.” The X-6A has a
of UK Research Huntress II Turbojet. The X-6A is designed hybrid electric-fuel system, a top speed
and Innovation. to be operated in adverse weather, and of Mach3, a maximum take-off weight
can take off in Force 10 storm conditions of 130kg and a payload of 50kg, an
and ground-level icing. The unmanned endurance of 120 minutes and a ceiling
aircraft, which has multiple of 6,000m above sea level (approx.
use cases including 20,000ft). And the unique design of the
emergency response UAV is inspired by the animal kingdom,
and reconnaissance specifically the Californian Condor.
missions, is the “WaveAerospace takes its cues from
latest product from the world around us - from nature’s
WaveAerospace, which most extreme creatures to the newest
builds unmanned aircraft technologies from around the world,” the
that can fly in wind company said in promotional material
that would ground released earlier in the summer.
other aircraft. “The result is a new class of aircraft with
WaveAerospace’s unique abilities and, thus, potential utility
CEO Mark in myriad new operations. That’s why our
Strauss said: “We aircraft is the size it is. That’s why it has
‘X’ oriented wings.”

Checking In
ABOVE: Which of these start-ups is most
The X-6A features a central turbojet and likely to succeed, and why?
wingtip propulsors for control WaveAerospace
Share your view at
TOP RIGHT: [email protected]
Its technology and manufacturing processes could under the subject heading Checking In.
revolutionise how aircraft are made, Steelo says Steelo

October 2022 AIR International 55

 Alive and
kicking
Known as the world’s most numerous
attack helicopter, the Mi-24/35 Hind is
still in production in Russia, with a series
of upgrades and continuing interest from
operators. Alexander Mladenov reports

56 October 2022 AIR International

 aunched in the early 1970s placed by both domestic and export The redesigned and digitised Mi-35M/Ps are being

L
and with more than 3,600 customers alike. promoted as leading the way as potent and well-
armoured gunships, endowed with round-the-clock
built, the iconic Hind is still Current demand for the armoured attack
attack capabilities and improved guided weapons
enjoying export demand for type promises that the production of the Russian MoD
new-build machines. Mi-35P/M family at the Rostvertol plant in
The renaissance of the the southern part of Russia is expected to
Mi-24/35P/35M family of continue until the mid-2020s.
attack helicopters happened, somewhat As many as 177 new-build and pumped-
unexpectedly, during the mid-2000s, up Mi-35Ms were delivered to ten
while the early 2010s saw a hike in the different export operators between 2005
production of the type, with numerous and early 2022 in addition to the Russian
orders for newly built Mi-35Ms being Aerospace Forces (RuASF) and the air

October 2022 AIR International 57

 for close air support (CAS) and
counterinsurgency (COIN) operations,
featuring good battlefield survivability,
sufficient firepower, plus precise 24-hour
aiming and targeting capability.
The pumped-up Hind sports a significant
number of airframe changes, combined
with rotor system replacement through
RuASF’s Army Aviation Branch took its
first two Mi-35Ms in December 2011
use of a main rotor hub and composite
and deliveries continued until 2019 blades, and an X-shaped low-noise tail
Russian MoD rotor borrowed from the newer-generation
Mi-28N.
The most significant changes include
shortened stub-wings with only four
weapons stations (compared to six
on the older Hind versions) and non-
retractable landing gear. According to Mil
designers, the non-retractable landing
gear introduced on the Mi-35M improves
the crash-landing survivability during
ultra-low altitude flight.
There were also measures taken
to improve the helicopter’s combat
survivability by beefing-up the armour
protection, adding new protection
for vital systems and introducing
arm of Russia’s Federal Security Service together with the option of using redundancy in the oil system and the
(FSB), while at least 30 more examples of affordable guided and unguided flight controls. The Mi-35M also has
are slated to roll off the production line ordinance and new-generation self- an anti-surge system protection for the
until 2025. protection aids. engines when ingesting powder gases
Currently, the Russian attack machine, The enhanced Hind also offers the from salvo rocket launches.
the baseline design of which flew for unique ability to transport up to eight The new-generation Hind comes
the first time 53 years ago, is readily fully equipped troops, munitions or other powered by the up-rated Klimov
available in the form of two new- cargo weighing up to 3,306lbs and up VK-2500-02 turboshaft, rated at 2,200shp
generation derivatives, with two upgrade to 5,289lbs on an external sling. The for take-off and 2,700shp in the one
configurations also on offer. versatile and armour-protected cabin can engine inoperative (OEI) emergency
Key to the continuing export interest also be rapidly converted for casualties. mode. The more powerful engines,
in the enhanced Hind is the reasonable combined with a more efficient rotor
price of an aircraft with good hot and New generation HIND system, grant important performance
high performance, enhanced armour The Mi-35M, the ultimate Hind derivative, gains in hot and high operating conditions
protection and digital mission avionics flown for the first time in the early 2000s, compared to the legacy Mi-24/35
package for day/night operations, is well-suited to meet the requirements versions, in addition to much improved

Expanding customer base

To date, the enhanced new build ‘Hind’ has
been sold out to at least 12 export customers
and the type could have at least five more
export customers in the foreseeable future.
• Azerbaijan -24
• Brazil - 12
• Iraq - 28
• Kazakhstan - 12
• Mali - 3
• Nigeria - 8
• Pakistan - 4
• Serbia – 4
• Uzbekistan - 12
• Venezuela – 10
• Russia - 60
Russian Aerospace Forces – 55
Federal Security Service - 5
The Mi-35M has also been ordered by
Belarus (the order is covering up to 12
examples), with deliveries expected in the
second half of 2022 or the first half of 2023.
The list of the potential customers in the near-
to medium-term includes Armenia, Angola,
Peru, Myanmar and Syria.

58 October 2022 AIR International

The combination of a lower price tag compared
to the Mi-28NE and Ka-52, plus a high degree
of commonality with the legacy Hind derivatives
operated by tens of counties around the world,
still makes the Mi-35M a cost-effective proposition
for customers in developing countries
Serbian MoD

flight safety margins when flying on one Better armed The unguided arsenal comprises the
engine. The combination of the all-new The beefed-up weapons suite saw S-8 family of 80mm rockets unleashed
rotor system and up-rated engines has the introduction of the 9M120 Ataka-V from 20-round B8V-20A packs and the
resulted in the Mi-35M’s service ceiling Spiral-2 anti-tank guided missile (ATGM), large S-13 122mm rockets from B13L five-
increasing by some 985ft – up to 10,170ft also borrowed from the Mi-28N. Up to round packs. At the same time, however,
in standard conditions, while the rate of eight Spiral-2s can be carried on a single the Mi-35M lacks the ability to employ
climb reached 2,440fpm. eight-round launcher, using the line- free-fall bombs, KMGU-2 bomblet/mine
of-sight radio guidance method, and dispensers and the older 57mm and
sporting a maximum range of 3.13nm. 240mm rockets.
The missile’s baseline version, fitted The new weapons pylons with built-up
with a tandem warhead, optimised for hoists can also carry up to four 575-litre
penetrating explosive armour protection of underwing fuel tanks for ferry flight. The
modern tanks, boasts a claimed armour extended range/endurance operations the
penetration capability of up to 850mm. Mi-35M are possible thanks to the ability
There are also Ataka-V sub-versions to carry two rocket packs or gun-pods in
fitted with thermobaric/high explosive addition to two external fuel tanks.
and blast-fragmentation warheads, the
latter also equipped with a proximity fuse, New mission avionics
making it suitable for engaging slow- The significantly expanded navigation/
speed air targets. flight and targeting capabilities are
The Hind air-to-air combat ability has centred around the KNEI-24 affordable
been beefed up thanks to the integration digital avionics package (performing
of the Igla-V Grouse missile with a enhanced nav/flight functions) and the
range of up to 3.2nm, accommodated OPS-24 observation/targeting package
in twin launcher packs. The lightweight for day/night combat operations. Its
missile, repurposed from a shoulder- main component is the UOMZ GOES-
launched SAM, is advertised as a suitable 342 gyro-stabilised payload, integrating
weapon for anti-UAV and anti-helicopter a forward looking infrared (FLIR) sensor,
operations in addition to self-defence. Sony TV-camera, laser-rangefinder
Guns in the helicopter’s arsenal are and infrared goniometer device. The
represented by a GSh-23L 23mm twin- payload’s FLIR sensor is claimed as
barrel system with 470 rounds in a nose- being useful for detecting tank-size
In November 2013, the Iraqi Army Aviation Service
got its first Mi-35Ms. A total of 28 examples
mounted NPPU-23 turret, complemented targets at night at up to 3.2nm while
were taken on strength, this way making Iraq the by one or two UPK-23-250 gun pods, in daylight the TV sensor sports useful
biggest export customer for the type Iraqi MoD containing the same GSh-23L gun with detection ranges of up to 5.4nm.
250 rounds each. The weapons control system is built

October 2022 AIR International 59

 around the BVK-24 weapons control
digital computer and laser rangefinder
unit to improve the precision of delivering
unguided weapons. All forward-firing
unguided weapons are aimed by the
1970s-vintage VG-17 electro-optical sight
while the newer and much more capable
ILS-28 HUD was seen installed for the
first time on the helicopters built for
Kazakhstan in 2016.
Navigation accuracy of the Mi-35M has
been significantly enhanced as a result
of the introduction of an A-737-00 highly
precise satellite navigation receiver unit,
working with both GPS and GLONASS
systems and integrated with the existing
DISS-15D Doppler sensor.
The Mi-35M’s day/night operating
capability becomes possible thanks to the
night-vision goggle (NVG)-friendly cockpit
illumination. Cockpits of the Mi-35Ms are
compatible with the Russian-made GEO
ONV-1-01 Gen III NVGs. Featuring a field
of view of 40 degrees, the ONV-1-01’s
target-detection range (against tanks or
trucks) is up to 3,300ft and the NVG set
also permits low-level flight at night down
to 160ft.
The baseline Mi-35M retained a
defensive aids suite largely inherited
from its predecessor Mi-24V/P,
comprising several 1980s-vintage
‘federated’ systems, including the SPO-
15 radar warning receiver (RWR), UV-26
countermeasures dispensers for ejecting
flares and chaff cartridges, EVU exhaust-
mixer boxes over exhaust ducts for
reducing the acquisition range of heat-
seeking missiles as well as the SOEP-V1A
omni-directional IR jammer.
The enhanced self-protection suite for
the RuASF Mi-35M fleet was introduced
in early 2016 and has been installed on
a significant proportion of the fleet. The
Vitebsk-35 integrated suite is intended
for use against heat-seeking missiles and
consists of an L370-2-01 ultraviolet (UV)
missile approach warning system installed
in pronounced conformal bulges in the
forward and rear fuselage in addition
to three L370-5 directional infrared (IR)
jammers. Two of these are installed on
the fuselage sides and another unit is
suspended under the tail boom. The
IR jammers operate in conjunction with
the existing UV-26 countermeasures

THIS PAGE FROM TOP:

The continuing export demand for the new-build
Hinds is expected to keep the production line up and
running at Rostvertol well into the mid-2020s
Alexander Mladenov

The current backlog and the expected demand for

the Mi-35P/M would guarantee a busy Rostvertol
production line at least until the mid-2020s
Alexander Mladenov

An armoured attack helicopter with sophisticated

targeting systems and guided weapons, additionally
the Mi-35M has a robust assault transport capability
– its spacious cabin can hold eight fully equipped
troops via Alexander Mladenov

60 October 2022 AIR International

Mi-35P flexible upgrade package
In addition to new-build Mi-35Ms, and has been marketed as an
Russian Helicopters, the umbrella affordable option for export operators
holding company controlling the around the world who are aspiring
type’s design authority, Mil Moscow to upgrade their existing Mi-
Helicopter Plant (Mil MHP), and 24D/V/P or Mi-35/P fleets. It was also
Rostvertol production plant, began at initially expected that this relatively
last in 2018 to offer a comprehensive affordable upgrade package will be
upgrade package for older- embraced in Russia, as the RuASF’s
generation Hinds rolled out in the Army Aviation service still operates a
1980s and the 1990s. relatively large fleet of Mi-24Ps with
Another new derivative from the a lot of service life remaining in them.
enhanced Hind family, the Mi-35P, These machines would be suitable
was unveiled at the Army-2018 for undergoing a cost-effective Mi-35M/P’s main armament consists of up to eight Ataka-V or Ataka-1 affordable
defence exhibition in Kubinka near upgrade to boost their overall combat tube-launched anti-tank guided missiles with a maximum range of 3.13nm or
Moscow. It is seen as the long- capability and provide good day/ alternatively up to six Vikhr-1/1Ms (seen here), with up to 4.2nm range
Alexander Mladenov
awaited ultimate upgrade standard night operating potential for ten to
as originally promised by Mil MHP 15 years to come. As of July 2022,
and Rostvertol in the early 2000s. however, there was no confirmed
Work on this significant upgrade information that the Mi-35P upgrade
package was abandoned soon after standard had ever been ordered by
the first orders were received for the Russian military for breathing a
newly built Mi-35Ms. In 2017, at second life into the RuASF’s existing
last the upgrade configuration was Mi-24P fleet. It is also expected that
reviewed. Development and testing the Mi-35P standard could be offered
took no less than three years, with in a new-build form.
first flight reported in 2019 and The Mi-35P standard features
testing completion announced August the enhanced targeting and flight/
2020. navigation suite inherited from
Compared to the new-build Mi-35M the enhanced Mi-35M derivative
standard, the Mi-35P incorporates unveiled in 2018 (including the OPS- The air-to-air capability for the new-generation Hind is provided by the integration
a more modest number of novelties 24N-1L, PrVK-24-2 weapons control of the 9M342 Igla-S heat-seeking missiles with a range is of up to 3.2n,m carried in
Srtelets twin-round launcher packs Alexander Mladenov
computer and KNEI-24E-1 flight/
navigation/display system), together
with its new weapons while retaining
the airframe, rotor system and
powerplant of the legacy Mi-24/35
family unchanged. A life extension is
also to make the upgraded enhanced
Hind fit for use for no less than 40
years and 4,000 flight hours.
The Mi-35P boasts the capability to
fire both the 9M120-1 Ataka-1 and
Vikhr-1/1M ATGMs with laser-beam
guidance and has the NPPU-23 gun
turret with a newly installed GSh-23L
twin-barrel cannon and 250 rounds
instead of the Mi-24V/P’s YakB-12.7
machine gun or GSh-2-30 cannon.
The Mi-35P retains the original The Mi-35M’s OPS-24 observation/
targeting package is centred around
stub-wings provided with large-size the GOES-342 payload under the
endplates, used to support pods nose, integrating a FLIR, Sony TV-
with self-protection equipment camera, laser-rangefinder and infrared
(missile approach warners), together goniometer, while an improved
with the retractable undercarriage derivative unveiled in 2018 also sports
and the legacy TV3-117VMA a laser-beam missile guidance system
Alexander Mladenov
engines rated at 2,225shp each at
OEI mode. A three-turret system The old-style rotor system,
with IR- or laser-based directional combined with retractable
jammers to counter heat-seeking undercarriage and TV3-117VMA
missiles can be added as a engines, provides the upgraded
customer-selected option. Hind with a better performance in
The new PKV-8-35 digital autopilot terms of speed than the new-build
The Mi-35M comes armed with a nose-mounted GSh-23L twin-barrel gun in the
facilitates much better stability and Mi-35M; its maximum speed is
NPPU-24 turret provided with 470 rounds, and the gun armament can also include controllability performance compared 181kt (335km/h) compared to the
two UPK-23-350 pods with the same GSh-23L, provided with 250 rounds to the legacy Mi-24 family, thus Mi-35M’s 162kt (300km/h) while
Alexander Mladenov reducing the pilot workload. cruise speed is 140kt (260km/h).

October 2022 AIR International 61

 LEFT:
A scan inside the Mi-35M’s pilot cockpit
Via Alexander Mladenov

BOTTOM:
The Mi-35M is a facelift of the Mi-24/35 family of
attack helicopters and combines a large number of
airframe alterations with a new rotor system using
the Mi-28N’s main rotor hub and composite blades
and the X-shaped low-noise tail rotor
Russian MoD

daylight but during night engagements

the Vikhr-1’s range is limited by the
performance of the FLIR sensor of the
OPS-24N-1L targeting system.
This latest newly built Hind derivative
is also being offered equipped with the
President-S35 integrated self-protection
suite as an option. This is the export
derivative of the L370 Vitebsk, already
retrofitted to the VKS Mi-35Ms in addition
to a beefed-up armour protection for a
further beefed-up battlefield survivability.
The flight/navigation suite also has
expanded capabilities thanks to the
Western-standard navigation aids
offered for integration in it such as the
dispenser units as the jamming effect is package sports a maximum range of up Russian-made VIM-95-35 ILS/VOR and
being enhanced by pumping out IR flares to 5.4nm in daylight for detecting tank-type VND-94 DME systems. The radio suite,
from the dispensers, in the automatic targets, with a claimed recognition range which in the standard version includes the
mode upon commands issued upon of up to 4.3nm in optimal conditions. KSS-28NE advanced communications
activation of the missile warners. The beefed-up arsenal is represented suite with two VHF/UHF and one HF
by the laser beam-riding Ataka-VM radios supplied by the Russian company
HIND on steroids ATGM with 3.2nm maximum range with Prima, could be replaced by foreign-
A further enhanced Mi-35M derivative up to eight missiles carried on a single made radios upon customer request. This
was unveiled for the first time at the launcher. It also comes armed with the capability was already provided during
Army-2018 defence exhibition held in newly integrated 9K121M guided weapons the production of the helicopters for
August 2018 in Kubinka near Moscow. suite including the 9A4172K Vikhr-1 ATGM Venezuela and Brazil.
Aimed mainly at export customers, this Scallion, a long-range, hard-hitting missile The Hind has come a long way since
pumped-up facelift sports a further originally developed for the Ka-50/52 its launch. The type leads the way as a
improved targeting suite centred around family. This missile also employs the heavyweight-class battlefield machine
the OPS-24N-1L day/night observation/ highly precise laser beam-riding guidance, and the latest versions of former Cold
targeting package, utilising an enhanced- providing the enhanced Hind on steroids War rotary-wing warrior – the most widely
performance IR long-wave detector matrix with a useful stand-off engagement used attack helicopter of all time – are
for its FLIR sensor and provided with capability. Carried on a six-round launcher, set to continue their faithful service for
laser beam-riding targeting capability. The its maximum range extends to 5.4nm in decades to come.

62 October 2022 AIR International

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316/22
 ZOË ASHF
Cranfield University student Zoë Ashford
tells Tara Craig why space matters

W
ithin hours of Space companies should be doing
submitting her more in terms of STEM and other
MSc thesis, outreach, but generally in the UK, there’s
Zoë Ashford not a great understanding of what
sat down with engineering involves.
AIR International In Germany, for instance, the professional
to address title for an engineer – Ingenieur – is
everything from promoting the value protected by law, giving the holder a
of science to the public’s failure to certain standing and recognition of their
appreciate engineering. qualifications. Here, however, the public
has little concept of the huge wealth of
Q What first interested you in space? work being done by engineers just to keep
As a kid, everyone finds space fascinating. the world running. The more we can do to
It represents danger and the unknown. raise awareness, the better.
And I've always really loved science fiction
– Star Trek, Star Wars, and the books of Q Tell me about your outreach work
Iain M Banks and Alastair Reynolds. What I set up a STEM programme last year.
really appealed to me is the combination of Volunteers from Cranfield gave talks to local
imagination and wondering how you could schoolgirls, later mentoring them for the
make something work. Because a lot of the CREST Awards, a national STEM scheme.
things that sound very exciting are based We also put together The Mars Rover
on very basic principles – a rocket engine is Workshop. I bought a £13 stomp rocket,
just expanding hot exhaust gases. designed a paper sheath that went over
My first degree is in Chemistry and I it to make it wider, and then made a
started out in the submarine industry as 10cm adapter that sat on top of that. We
an engineer. At New Year 2019 a friend gave the students 45 minutes to design,
gave me a book that changed everything – build, and launch a rover. The materials
Ignition! An Informal History of Liquid Rocket included toothpicks, paper cards and
Propellants by John D Clark. I read it and Sellotape stickers, and they had to take
thought, “I should go and do that”. two scientific payloads – LEGO bricks.
The whole thing had to fit inside a 10cm
Q Who are your space heroes? by 5cm payload fairing. We’ve run this
I admire all the great pioneers and have workshop five times and every single team
a lot of time for Helen Sharman and has launched a rover. And every single
Tim Peake, who works hard to promote time we saw different techniques.
STEM [science, technology, engineering
and maths] for young people. We see Q Tell me about your IAWA scholarship
astronauts as figureheads but their The International Aviation Women’s
achievements are a culmination of billions Association is an amazing community.
of hours’ work by hundreds of thousands Meeting other women in the engineering
of people. What I find most exciting is industry has been exciting. It's reassuring as
rocket development and what’s behind it. well because it reinforces that we're here and

Q How can the space industry

we're achieving. It was a huge honour to win
this but also a good vote of confidence in my
As a kid, everyone
recapture the public imagination?
The UK space industry is in its infancy
decision to come to Cranfield to study space. finds space
but hopefully in the next few years we Q What advice would you give anyone fascinating. It
will see launches from the likes of Orbex planning to work in the space sector?
and Skyrora. And while launches are very Based on the demographic on Cranfield represents danger
glamorous things, statistically speaking it’s space courses, [I would recommend]
very likely that each new launch vehicle will a traditional background – aerospace and the unknown
suffer some catastrophic failure. Not only is engineering, or maybe mechanical or
this preferable early on, with a test payload, electrical engineering. If your background
but it will bring a certain sense of drama is different, embrace it – understanding
that gets people invested. propellant chemistry helped me.

64 October 2022 AIR International

HFORD

October 2022 AIR International 65

 People will often
overlook or dismiss
what you say because
of your gender

Q Is it harder for women in the sector? We opted to launch both a rocket and a
There are women in the industry, but what payload. We made our electronics very,
doesn't help is that most space start-ups very robust, and we also designed and
in the UK are very heavily male-dominated. launched a CanSat [a mini satellite the size
The bigger engineering companies tend to of a drinks can].
make more of an effort in terms of diversity Taking part in Mach-22 was immensely
and inclusivity. I would say that only between exciting for two reasons. Firstly, because
10 and 20% of my class here is female. I had waited so long to launch this
There are times when you are aware of that. rocket. It was incredibly cathartic to see
I think having some industry experience it launch. And secondly, because most
gave me a degree of credibility, but I have rockets launched in the UK, especially by
found that people will often overlook or students, are single stage. Ours, however,
dismiss what you say because of your was a two-stage rocket, meaning that a
gender. They make assumptions about second motor propels the rocket even
your capabilities, and the only thing you further, helped by jettisoning half the
can really do is learn to present yourself structural mass. Knowing that we had
calmly and with confidence. done that felt amazing.
The main thing we took away from
Q Tell me about Mach-22 Mach-22 was the improvement to
The Mach-22 Launch Competition took our test procedure. It wasn’t a case
place earlier this year on the Machrihanish of launching something every weekend –
Airbase in Argyle. This is its second year, we only had one go.
and it was designed ‘to give university It cost almost £1,000 for the motor and
students an opportunity to develop the casings so we had to be sure that it
practical, hands-on mechanical and would work. That kind of discipline made
electronics skills’. This was the first time it a valuable exercise.
CranSEDS [Cranfield Students for the
Exploration and Development of Space] Q How will space technologies benefit
had entered [Zoë is president of the mainstream aviation?
university branch of the UK’s national I think the big one will be liquid hydrogen
student space society]. handling. And the reason I say this is
We had designed a two-stage, 3km, that liquid hydrogen is a commonly used
commercial, off-the shelf solid motor propellant for rockets and the space
rocket for EuRoC – the European Rocketry industry is developing expertise in handling
Challenge – in 2021. A last-minute electronics it, particularly in terms of long-term storage.
failure meant that we were unable to launch I think it will see increased use in aviation
it, which was heartbreaking. We modified it and the sector will look to the space
for Mach-22. industry for expertise.

66 October 2022 AIR International

Q Tell me about your MSc Airbus, essentially – would be fantastic. I CLOCKWISE FROM ABOVE:
Well, I submitted my thesis today – would love to work on launches. The STEM outreach and mentoring programme saw
its title was Design of a 3 kN LOX/ Cranfield volunteers work with local schoolgirls
All images: Zoë Ashford
Hydrocarbon Film-Cooled Demonstration Q Finally, how do you feel about
Engine. On the course itself, I took, billionaires going to space? The CranSEDS team before the launch of its rocket at
among other things, two astrodynamics They drive technological advancements Mach-22 on Argyle’s Machrihanish Airbase
modules – looking at how satellites move such as the Falcon engines developed
in space, and at spacecraft attitude, by SpaceX. Then there was the Zoë Ashford preparing for CranSEDs’ Mach-22 launch
dynamics, and control. Virgin Galactic crash in 2014; it was
I have secured funding for a PhD and unfortunate but it made everyone look at
will be speaking to a supervisor tomorrow their process procedures very carefully.
to discuss potential topics. I would like to The downside is that it can be harmful to
build and fire something, but it would need public perception of the space industry,
to have a research purpose. because people may see it as a fun thing.
After that, I would like to go back into That ignores the amazing technological
industry and ideally work for one of the developments that went into making it
big launcher companies. To be part of the work. It also leads to the more serious
group that makes the Ariane rockets – missions being ignored by the public.

To be part of the group

that makes the Ariane
rockets – Airbus,
essentially – would
be fantastic

October 2022 AIR International 67

 S EA KINGS, SAR a

HeliOps’ Sea King HU5 (serial XV666 Damien) landing on one of Dorset’s beaches. The expert training that students receive on
the Sea King is applicable to all rotary types, as well as giving them the opportunity to fly a legendary aircraft
All images: Ian Harding/Kevin Wills
 An exciting new era
in rotary operations
is underway on the

and much more

UK’s south coast,
as Ian Harding and
Kevin Wills discovered
when visiting one of
its premier specialist
helicopter providers

S
teeped in naval history
and tradition, the Isle
of Portland on Dorset’s
world-renowned Jurassic
Coast is once again
reverberating to the sound
of rotary aviation. The
Royal Navy's Westland (now Leonardo)
helicopters such as the Lynx, Wasp,
Wessex and Whirlwind of past years
have been replaced by HeliOperations’
distinctive orange and grey Westland
Sea Kings, which now grace the skies
above the famous island.

Commercial expansion
Under the stewardship of its chief
executive officer, Steve Gladston, and
chief operating officer, Mark Deaney,
HeliOperations – or HeliOps as it is
better known – has become one of the
UK’s premier providers of search and
rescue (SAR) and other bespoke aircrew
training, plus a broad range of specialist
aviation services.
The growth in the HeliOps brand is
testament to the service it provides
and its many years of naval flying and
engineering experience. The HeliOps
team comprises former military pilots,
rear aircrew and engineers who fully
understand the operational environment
and have the appropriate skills to operate
military aircraft. In Steve Gladston’s case
this was gained as a Royal Navy Sea
King pilot flying anti-submarine warfare
(ASW) and SAR missions and as a civilian
operator of Sikorsky S-61s and S-92s.
HeliOps’ chief pilot, John Bentley, has
spent 30 years in commercial SAR and
flying support operations for the oil and
gas industry, the military and the United
Nations (UN).
Having successfully transitioned Ireland’s
SAR capability from the S-61 to the S-92,
HeliOps’ extensive experience has served
them well supporting Portland’s Maritime
and Coastguard Agency (MCA) operations
through the provision of aircrew. As Steve
Gladston explained: “Our aim has always
been to provide outstanding service to
our customers and in going beyond

October 2022 AIR International 69

 CLOCKWISE FROM ABOVE: compliance, to provide safe, reliable, King operations to provide continued
ZA166 is pictured completing both low- and and flexible delivery of our training support to the Federal German Navy
high-level training near Golden Cap on Dorset’s courses. While we have faced challenges, (FGN) and others, we are planning
Jurassic Coast. At 191m (626ft), Golden Cap is the particularly when seeking to be innovative, significant expansion into civil-based
highest point on the south coast of Great Britain
our approach to assembling specialist activity, including SAR training and other
Sea King maintenance underway inside the HeliOps teams with the required knowledge and areas. This is likely to require additional
hangar complex at Portland experience has paid dividends. Our capacity at Portland and elsewhere. We
customers are exceptionally happy with expect that the next 6-12 months will see
Two Royal Navy Merlin HC4s taxi on Portland’s the training we deliver and the way in rapid expansion in a number of areas.
runway prior to being refuelled at HeliOps on their which we adapt to changing requirements Watch this space.”
return flight to RNAS Yeovilton from HMS Queen
quickly and seamlessly.
Elizabeth (R08) on its initial global cruise. An RAF
Chinook HC5 can also be seen in the distance, “For the future, while we will be Expansion
moments before touchdown consolidating our military-registered Sea While Portland Heliport represents the
most prominent aspect of the HeliOps
operation, the company has expanded
considerably since 2017. It has a wholly
owned facility in Somerton, Somerset,
located approximately 35 miles from
Portland. With more than 3,000sq ft
of space available, this Military Part
145-approved storage and on-site
maintenance facility provides HeliOps
with the capability it requires to
maintain its Sea King helicopter fleet,
air systems and components. The fleet
now comprises 18 aircraft: six former
Royal Navy 771 Naval Air Squadron
(NAS) HU5s, seven former airborne early
warning (AEW) ASaC7s – which served
with 849 NAS until they were retired from
service in September 2018 – and five
former Royal Air Force (RAF) HAR3s.
HeliOps has also acquired the former
Royal Navy Sea King simulator located at
Royal Naval Air Station (RNAS) Culdrose
in Cornwall. This world-class facility has
developed an enviable reputation over
many years of Sea King operations with a

70 October 2022 AIR International

 Operations at Portland
Portland offers aviation enthusiasts a rare
opportunity to see operational Sea King
helicopters and, if you are fortunate, a
number of current military and civilian
helicopters, notably AW101 Merlins, AW159
Wildcats and Boeing CH-47 Chinooks.
HeliOps provides support to the British Army
Air Corps, RAF and Royal Navy, who all
undertake refuelling when operating in the
area. HeliOps also supports Her Majesty’s
(HM) Coast Guard's rotary SAR operations
as required and has also supported other
emergency services air assets including
the police and the air ambulance. Added
interest is also often provided by the US Air
Force Bell Boeing CV-22B Ospreys from the
352nd Special Operations Wing’s 7th Special
Operations Squadron (SOS), based at RAF
Mildenhall, Suffolk, which also refuel at
Portland when necessary.
Steve Gladston is confident of the
company’s future at Portland: “The last four
wide variety of international users. own aircraft. We maintain the aircraft years has seen HeliOps develop capability in
Steve Gladston explained the to the same high standards as when in both depth and breadth. We deliver what our
importance of Somerton and Culdrose military service and, having procured from customers require – safe, reliable and
to the business: “HeliOps provides a the UK MOD the full range of spares and cost-effective training using highly
full package to our customers. Flying support equipment, we are confident that experienced instructors, representative
courses are developed to provide the we will be able to continue to operate the equipment and comprehensive training
right balance between synthetic and Sea King for as long as our customers packages. We continue to develop our
live flying. The Sea King simulator is require it.” services and expand the customer base,
capable of training for full-mission profiles, and expect this to increase very rapidly over
including the use of night-vision devices German Navy contract the next few years. Our customer base is
and operating in the maritime, desert and HeliOps’ primary focus at present is expanding and we have responded to the
mountain environments. Somerton is the delivering SAR training to pilots from requirements by achieving a civilian CAA Air
most recent addition to our facilities and the FGN, which currently operates the Operators Certificate to enable training to be
gives us the capability to maintain our Westland Sea King Mk 41 in this role, provided to civilian and military operators.”
own or clients’ aircraft, and to store the deployed with Marinefliegergeschwader 5
full range of spares required to support (Naval Air Wing 5) from Nordholz Air Base HeliOps’ success working alongside this
our helicopters.” in northern Germany. key NATO ally is reflected by the fact that,
Germany was the first export nation since 2017, the company has successfully
Sea King for the Sea King, which was initially completed more than 15 training courses
The trademark for HeliOps operations delivered as a dedicated SAR platform and qualified 25 pilots. With the current
has been its two distinctive orange and between April 1973 and September FGN training course commencing August
grey Westland Sea King HU5s – XV666 1974. It would eventually receive 22 Sea 2021, both parties are working hard to
(nicknamed Damien) and ZA166 (Dara) Kings, which were upgraded during the maintain and develop the programme,
– although these have been joined mid-1980s to carry anti-ship missiles, for which is tailored to meet the FGN’s
relatively recently from an operational which the Ferranti Seaspray radar was specific requirements.
flying perspective by an all-grey example fitted to the nose radome. With the Sea This success has helped HeliOps
– XZ920 (Finley) – which the company King having been in service for almost secure other contracts, including one
plans to use to deliver additional 50 years, Germany received the first with Norway, another international Sea
capabilities to its customers. All three of 18 NHIndustries NH90 NFH (NATO King operator. In November 2020, the
aircraft are former 771 NAS aircraft that Frigate Helicopter) Sea Lion helicopters Royal Norwegian Air Force contracted
served with distinction until the squadron in October 2019. Ordered in 2013, these HeliOps to provide theoretical and
was disbanded at RNAS Culdrose in multi-role rotorcraft are scheduled to synthetic ASW training to its Lockheed
March 2016. replace the ageing Sea Kings in this role P-3C Orion students as they develop
Despite their maturity, these aircraft from 2023. their capabilities ahead of the introduction
are operated to the highest safety and While the Sea King enjoys legendary of five Boeing P-8A Poseidons, the first
airworthiness standards, with their flying status from an operational SAR of which rolled out in July 2021. Other
and engineering activities regulated by the perspective, fielding the aircraft does not customers include the Pakistan Navy and
Military Aviation Authority (MAA). As Mark represent the easy option for HeliOps. ETPS, the Wiltshire-based Empire Test
Deaney explained: “HeliOps operates the However, this was a prerequisite for the Pilots’ School.
Sea King to provide the representative FGN contract and, since 2017, HeliOps
training required by our customers, has effectively built an entire flying, Training flexibility
notably the German Navy. Developed airworthiness, maintenance and support In common with other nations, simulator
over many years by the UK Ministry of infrastructure for them based around the training plays an increasingly important
Defence (MOD), the platform provides Sea King HU5, which is fundamentally part in the conversion to type (CTT)
the ideal aircraft to deliver SAR training similar to the FGN’s Mk 41, with the very process for FGN aircrew. As good as
– it is well equipped, extremely stable and small differences between the models current day simulators are with their
highly representative of our customers’ covered by training provided by HeliOps. digital imagery and glass cockpits,

October 2022 AIR International 71

 Helicopters H135 prior to operational
service on the Sea King Mk 41, so there
is no denying that a degree of resetting is
required when aircrew arrive at Portland
for training. For starters, having trained
using a digital cockpit, new students
will now operate in an analogue cockpit.
While this may initially seem like a
backward step, in terms of ‘fundamental’
hands-on flying, it’s a step that will serve
them well. For pilots who have trained on
a digital aircraft in Germany, they also get
to fly a legendary aircraft type, which is a
memorable experience
The reality is that the training they
receive on the Sea King is applicable to
all rotary types, as Nick Chick, former
SAR (771 NAS) and AgustaWestland
test pilot, who leads the HeliOps crew
training explained: “When the FGN pilots
arrive for their current Command Training
course, they will have already been CTT
trained by HeliOps and have returned
to the SAR School following operational
time in Nordholz. They will initially return
to the simulator at RNAS Culdrose
to ensure that aircraft differences are
refreshed and that evolutions such
as autorotations, night vision goggles
(NVGs) and single engine work can be
rehearsed. Following two weeks and
around ten hours in the simulator, the
candidates will relocate to Portland and
then conduct a further 40 hours in a
50/50 split of daytime and NVG flights in
the Sea King [HU5].
“The customer has also requested
XV666 Damien performing high-energy various additional elements be added
manoeuvres off Dorset’s Jurassic coast into the package, and this has been
included as a tailored requirement. If a
their limitations are recognised when training. HeliOps is in the process particular event needs to be reviewed,
it comes to obtaining the experience of securing several additional SAR then the training team at HeliOps will
required to operate in harsh SAR contracts to be operated on the military identify the best route accounting for
environments, where flying an aircraft register and civilian register and these digital currency and time on analogue.
at its limits is just one consideration. will involve the addition of more modern The handling skills required will be
Digital replication appears to have no aircraft types. reviewed and the sortie profile re-flown
boundaries, but it simply cannot replace German student pilots currently receive to ensure that it has been correctly
a live mission over the sea, where their ab-initio training on the Airbus interpreted by the candidate.”
adrenaline, weather conditions and the
heart-pounding sense of real-life drama
cannot be replicated.
The main consideration here is being
flexible and finding the sweet spot
between synthetic and real-life flying.
The challenge is ensuring an appropriate
balance is maintained, which is hard
when a fleet starts ageing and it
becomes increasingly hard to maintain
flying hours. This is where HeliOps’
focus, tailored approach, aircraft and
flight training experience comes to
the fore. Given that global defence
budgets are sometimes restrictive,
leading to standardisation, this is not a
consideration for HeliOps, which can
tailor its training programmes precisely to
meet its clients’ requirements.
While the current training is delivered
on an analogue-instrumented Sea King,
this is mostly because that is the aircraft XZ920 Sea King HU5 Finley captured during Federal German Navy course training on the Isle of Portland.
for which the German Navy requires HeliOps currently operates three Sea King HU5s, all of which are former Royal Navy 771 NAS helicopters

72 October 2022 AIR International

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340/22
 Twin-win
What does the digital
twin have to offer
aerospace manufacturers
and their customers?
Mark Broadbent
finds out

Using the ‘digital thread’ has helped to

speed up the design and test of concept
models for Tempest BAE Systems

74 October 2022 AIR International

 ed by data from across an lower cost than previous programmes.

F
organisation’s systems, the BAE Systems engineers have been using
digital twin is a precision the digital environment to design, test and
virtual replica of a physical ‘fly’ Tempest concepts, developing the
object or process. It runs Tempest fuselage demonstrator shown at
directly alongside and in the Farnborough International Airshow in
constant sync with a live July 2022.
‘real’ system to monitor data. Minton said: “It’s been manufactured
Artificial intelligence and simulation to represent how a future fighter aircraft
modelling means advanced scenarios can fuselage could be produced and
be run to test different courses of action developed via a digitally-rich environment
and discover the impact of a decision at our Factory of the Future facility in
before it is made for real. [Warton] Lancashire. Data from intelligent
Necessary changes can be identified, robots, supply chain databases and
addressed and introduced more quickly, machines is digitally threaded together to
and more effective product support and deliver increased efficiency and accuracy
optimisation can be provided. Digital in the manufacturing process.”
twins help design new products, faithfully Boeing is another major OEM actively
recreating real environments to improve using digital twin technology. Linda
the effectiveness of simulation, modelling Hapgood, vice-president and programme
and analysis. manager of digital transformation, told
AIR International: “Digital engineering
BAE Tempest gives us the ability to rapidly develop and
This is especially useful for such a optimise complex aerospace systems
high-end industry as aerospace, and inside the computer to work out the
leaders at major firms are adamant design, manufacturing and services well
about the value digital twins provide. before any hardware is built. All our new
Iain Minton, technology capability programmes are model-based from the
delivery director, BAE Systems – Air, told start. Model-based systems engineering
AIR International that digital modelling enables our requirements to be traceable
is part of a wider systems engineering and accessible throughout the entire
approach that is “the next generation of design and development process to
how we will design, test and improve our ensure all components are synchronised
products throughout their lifecycle”. to the latest configuration and any
Digital modelling, Minton continued, requirements updates.”
“underpins the entire engineering lifecycle”
for the company’s Tempest programme A new approach
to produce the UK’s future combat air What capabilities does digital technology
systems in half the time and at significantly give aerospace companies that they

“Data from intelligent robots, supply chain databases

and machines is digitally threaded together to deliver
increased efficiency and accuracy”
Iain Minton, BAE Systems

October 2022 AIR International 75

 BAE Systems engineers have been
using the digital environment From Red Hawk
to design, test and ‘fly’ Tempest
concepts BAE Systems to Stratofortress
Linda Hapgood, vice-president and programme
manager of digital transformation at Boeing, gave
AIR International some examples of how digital
twins helped design new military platforms.
She said: “The T-7A Red Hawk advanced trainer
is among the US Air Force’s first aircraft, weapons
and satellite systems to be designed, built and
tested along a digital thread.
“The advanced trainer embraces advanced
manufacturing techniques to improve quality and
enhance performance.
“Using model-based engineering and 3D design
tools, the T-7A represents an aircraft with a 75%
increase in first-time quality, an 80% reduction in
assembly hours and a process that cuts software
development time in half.
“The aircraft moved from firm concept design
to first flight in just 36 months. We’ve been able
to ‘fly’ the Airpower Teaming System digital twin
thousands of times under different scenarios to
test aircraft performance, the mission system and
many other components necessary for capable
simply didn’t have before? Engineers have sensors and satellite connectivity on the attritable aircraft.”
The T-7A has not been the only Boeing military
increased freedom and flexibility, BAE’s physical engine to collect data, which is
aircraft to benefit from digital twin technology.
Minton explained: “Where previously we continuously relayed back to its digital
Hapgood continued: “The F-15EX has been
might have disregarded ideas on the twin in real time.”
transformed through digital design, increased
basis that they would be too expensive to The company continued: “The twin
automation and tooling and reducing hole drilling
produce and test, the digital environment then operates in the virtual world as – all of which results in improved first-time quality,
allows – and encourages – you to try the physical engine would on-wing maintenance and sustainment operations and
without the fear of failure, and enables and will determine how the engine is affordability over the course of the platform’s
you to achieve a solution quicker.” operating and predict when it may lifecycle. Flight and maintenance data allows
He continued: “We’re able to experiment need maintenance. customers operating the F-15 Eagle to develop
in a digital environment at a fraction of the “This also allows us to enact preventative condition-based maintenance models to improve
cost, and we can extend that environment engine maintenance, which can greatly predictive maintenance.”
to remote users – enhancing the level of reduce aircraft downtime and, in turn, Digital twinning is also being used on the US
pace and collaboration in the process. enhance reliability. Air Force’s B-52H Stratofortress, symbolic of a
“We can use the digital information to “The data analysis used by the digital far earlier and firmly non-digital era of aircraft
allow multiple skills to work on the data twin allows us to model a greater number design. Hapgood said: “The US Air Force uses
in parallel, reducing the time taken to of potential circumstances than physical Boeing’s digital twin methodology for the engine
generate the part and enabling automatic engine tests would ever allow, which replacement programme on the B-52.
linkages from intent of a feature to how results in a greater understanding. “These 3D and mathematical models of all
that feature is produced and supported.” “Using a digital twin, Rolls-Royce can physical hardware allow us to evaluate airplane
Minton added: “We find new and study and predict the physical behaviours performance without ever touching the airplane.”
innovative solutions by trying out more
ideas and refining the solution in a more Tempest
iterative way without all of the traditional model in the
physical time and cost constraints.” wind tunnel
BAE Systems
The benefits of self-updating
Digital twins are not just useful for
designing new products, but for
supporting operations of those that
are already in use.
As Rolls-Royce put it: “A digital twin
will continuously learn and update itself
using data from sensors that monitor
various aspects of the real-life product’s
environment and operating conditions. It
can also factor in historical data from
prior usage.
“In engineering terms, the use of
digital twins reduces the need to rely
on probability-based techniques to
determine when an engine might need
maintenance or repair. Our engineers
create a digital twin of an engine, which
is a precise virtual copy of the real-world
product. They then install on-board

76 October 2022 AIR International

that an engine would exhibit under very BAE Systems’ fuselage
extreme conditions. This allows us to demonstrator representing
model potential operational scenarios how a future fighter aircraft
entirely digitally.” fuselage could be produced
and developed BAE Systems
Closer collaboration
Digital technology is also enabling
manufacturers to work more
collaboratively with their supply
chains and customers.
Minton said: “We’re working with some
of our component suppliers to develop
and test the technology that would allow
us to conduct real-time inspections in
a virtual world.”
Boeing’s Hapgood commented: “We are
reimagining how work can be achieved
by breaking down data silos across our
enterprise to create a digital thread with
consistent lines of understanding and
sharing among engineers, designers and
production and operations teams.”
She said: “This lowers development
costs, reduces barriers to entry via
digital prototyping, identifies and solves
problems quickly and shortens production
timelines. Boeing’s digital transformation
is an enterprise-wide effort and we expect
the technology developed to be applied
across all products and services.”

Evolution
What further advances can we expect
to see in this field?
Boeing’s Hapgood said future defence
and government contracts will put
digital engineering at the heart of things
– to assist in collaboration, real-time
programme management, requirements
traceability, pre-planned software,
electronics and mechanical systems
upgrades. She said that “true digital
twins that include real-time feedback
from the physical system” are a prospect, Digital twins enable manufacturers to study physical behaviours an
with increased use of modelling and engine would exhibit under very extreme conditions Rolls-Royce
simulation technologies to better

predict, analyse and optimise systems.

The analytics and visualisation digital
technologies provide will be a greater part
of programme management, Hapgood
added: “Schedule milestones and events,
resources, risks, completion status and
more will be linked and accessible across
the digital thread.”
She said: “Digital twins of the
factory and production system will be
implemented widely across industries
(aerospace, automotive, electronics, etc)
with a focus on both the plant design
and manufacturing operations being
fully digital from concept design to
part delivery.”

The entire lifecycle

BAE Systems is also exploring how to
use digital twin technology for the entire
BAE’s fuselage lifecycle of a product, extending from
demonstrator in the
design to proving how it could operate,
Factory of the Future at
Warton BAE Systems
testing service performance, modelling
support solutions and providing

October 2022 AIR International 77

 in-service support. Minton said BAE
is “assessing all of these as to where
digital twin approaches can be made
possible and provide benefits” and how
digital ‘evidence’ can be used to support
airworthiness approvals.
Minton added: “It also allows us to
extend a shared knowledge of production
status so all parties can understand the
flow of material into the end solution
and ensure appropriate resources are
deployed to achieve the goal.
“We are also exploring how we can
look at digital twins of the facilities and
solutions used to produce and maintain
the product – in short, digital twinning is
not just about the product we make, but Boeing says the T-7A Red Hawk is among the US Air Force’s first
also the facilities and enterprises that we aircraft to be designed, built and tested along a digital thread Boeing
make it in.”
The capabilities that the digital twins
provide dovetail with the wider trend of
reducing emissions.
In July 2022, Boeing announced
Cascade, a new data modelling tool that
assesses the full lifecycle impacts of
renewable energy by accounting for the
emissions required to produce, distribute
and use alternative energy carriers such
as hydrogen, electricity and sustainable
aviation fuels.

Artificial intelligence
BAE’s Minton highlighted that further
advances in digital engineering will
involve integrating artificial intelligence The front fuselage of the first
Boeing-Saab T-7A Red Hawk
(AI) and machine learning “to enable the
was joined with its aft section
digital twins to interact with each other, in less than 30 minutes,
such that the impact of a change can witness to the benefits of
be fed through to understand the true model-based engineering
lifecycle implications”. and 3D design Boeing
He said: “We can use this knowledge to
further enhance the approaches to develop control and develop this further will
current and future solutions, enabling the
customer to have a better solution, or use
be key to harnessing that opportunity.”
Boeing’s Hapgood noted that “digital Checking In
it in a better way. twin technology is still evolving”, but she Digital twinning will save
“[The] digital thread is a means to enable added: “The digital thread is key to the manufacturers time and money,
all things to be connected, all things to evolution and the integration of the data. but what potential downsides
be modelled. “The more mature the digital thread and do you expect to see?
“In that respect, the opportunities are its connectivity to multiple domains, the
immense, and the data and knowledge more mature the digital twin. Share your view at
needed in managing it are exponential. “If the digital thread is disconnected, [email protected]
under the subject heading Checking In.
Use of AI and other technologies to the digital twin will not be as valuable.”

A B-52H Stratofortress at Minot Air Force Base,

North Dakota, on July 7, 2022. The US Air Force uses
Boeing’s digital twin methodology for the engine
replacement programme on the Stratofortress
US Air Force/Senior Airman Michael A Richmond

78 October 2022 AIR International

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 The ability to support and
sustain operations in theatre
is paramount for air forces
hoping to gain a strategic
advantage. A significant part
of this is aerial refuelling.
Tim Fish takes a look at the
latest developments

An artist’s impression of
the LMXT boom as seen
from the receiving aircraft.
New A3R technology is
designed to automate this
process and reduce risk
Lockheed Martin

Tanker
T
anker aircraft are essential They are, therefore, strategic assets that include Belgium, Czech Republic,
for any military that seeks as they serve as a force multiplier and Germany, Luxembourg, the Netherlands
to conduct expeditionary or mitigate against some of the weaknesses and Norway.
long-range air operations. of air power. With the use of drones,
It is the only platform that particularly larger ‘Loyal Wingman’ Airbus advances
can provide fuel for cargo types of unmanned combat air vehicles Since the MRTT first came on to the
planes and fighters in the (UCAVs), expected to accelerate in the market a total of 66 orders have been
air using an aerial refuelling capability to coming years it makes tankers an even placed to date and 51 have been
enable them to extend their reach. more important part of the inventory than delivered, according to Airbus. At 58.8m
Using tanker aircraft means air forces ever before. long with a wingspan of 60.3m the MRTT
can conduct re-supply missions for their But the market for top-of-the-range new has a maximum fuel load of 111,000kg
forces deployed far from home shores next generation tankers is limited. The and a maximum cargo load of 45,000kg.
by extending the operational range of most successful product in recent years In place of the cargo, it can act as a
its airlift capability. It also means that has been the Airbus A330-200 Multi-Role transport for up to 300 passengers or
combat aircraft can remain on patrol Tanker Transport (MRTT), which converted with stretchers for medical
for long durations, providing air defence dominates the market outside of the US. evacuation. Refuelling can be provided
of important assets or allowing them to Since its launch in the early 2000s, it has by the Airbus Military Aerial Refuelling
conduct long-range strike missions on been selected to replace older fleets of Boom System (ARBS) or using a pair of
enemy targets that would normally be tankers by more than a dozen countries, underwing hose and drogue pods and a
too far away. Tankers are also vital for the including Australia, France, Republic of fuselage refuelling unit.
sustainment of ground forces deployed Korea, Saudi Arabia, Singapore, Spain, The latest development took place in
overseas where the delivery of essential UAE and the UK. July 2022, when the company announced
fuel supplies cannot be provided rapidly It has also secured sales with NATO’s at the Farnborough Air Show that MRTT
over land or via the sea. Multinational MRTT Fleet (MMF) members had become the first tanker to become

80 October 2022 AIR International

 A USAF refuelling boom operator from the 100th Air
Refueling Wing’s 351st Air Refuelling Squadron on a
KC-135 Stratotanker during NATO operations in the
Adriatic in July 2022. This work should be easier
with 3D visual systems on the new KC-46A aircraft
USAF

troubles
qualified for automatic air-to-air refuelling
(A3R) using a boom in daylight following
a series of test events with the Republic
of Singapore Air Force. As part of its
SMART MRTT, the company stated that
the A3R system “requires no additional
of a glass window while controlling the
refuelling systems. This requires more
autonomous boom and hose/drogue
control systems that use more automation
and Artificial Intelligence (AI) to improve
this kind of operation by lowering crew
selected the C-390 for its project to
replace its existing C-130H, albeit in the
cargo variant.
The C-390 is focused on a different
market: “As a multi-role aircraft, the
C-390 Millennium enables the operators
equipment on the receiver aircraft and is workloads and reducing risk. to streamline the overall number of
intended to reduce air refuelling operator Embraer has seen some success with platforms they need to operate and
(ARO) workload, improve safety and its C-390 Millennium multi-mission aircraft maintain, meaning more cost savings
optimise the rate of air-to-air refuelling that has been designed with a dual tanker and better use of the fleet,” the Embraer
(AAR) transfer in operational conditions to and transport role – it can be converted spokesperson said. This suits smaller
enable air superiority”. from one to the other in a short period of militaries with limited budgets.
time by installing the respective modules.
Embraer versatility “This versatility is important to Boeing and Lockheed
A spokesman from Brazilian aircraft nations that cannot afford a dedicated But the need to streamline platforms
manufacturer, Embraer, told AIR fleet of tanker aircraft,” the Embraer is not a concern for the US where the
International that the introduction of A3R spokesperson said. The company has US Air Force (USAF) operates in excess
systems had been the main change in delivered five aircraft of a total of 21 of 550 tankers. This is a huge fleet
tanker technology in recent decades. A3R currently on order. It has also secured that outnumbers the rest of the world
uses 3D cameras to provide vision for contracts to deliver five KC-390 variants by more than 2:1. Here, the market is
refuelling operators. The spokesperson to Portugal and two to Hungary. The dominated by Boeing and its KC-46A
said this replaces the operator stations initial deliveries to those countries will be Pegasus platform, which is being
located in the lower fuselage that require in 2023 and 2024 respectively. In June delivered under the KC-X programme,
operators to lie face-down to see out 2022, the Netherlands announced it had the first of three USAF projects

October 2022 AIR International 81

 designed to reinvigorate its strategic
The installation of the removable probe enables
tanker fleet. the Millennium to receive fuel from a tanker
KC-X, which was contracted in February and the underwing refuelling pods allows the
2011, will eventually total orders of Millennium to transfer fuel to other aircraft. The
179 aircraft, dwarfing the international fuel offload and the operational range can be
success of the MRTT. Boeing has also extended with the use of roll-on-roll-off fuel tanks
secured orders for the KC-46A from Embraer
Japan and Israel. A Boeing spokesperson
told AIR International that the company
“has delivered 63 KC-46A aircraft. 61 to
the US Air Force and two to the Japan Air
Self-Defense Force.” All the USAF KC-X
deliveries are supposed to be completed
by 2029.
Boeing’s KC-46A aircraft is based on the
KC-767A aircraft and is 50.5m long with
a wingspan of 47.5m. It has a maximum
fuel load of 96,200kg and a maximum
cargo load of 29,500kg and can operate
to a range of more than 11,830km. Its
cargo load can include up to 18 463L
pallets or space for 58 passengers or up
to 114 in an emergency. Refuelling can be
completed by a boom or drogue system.
Meanwhile, the next USAF project to
come on stream is expected to be the
KC-Y, or ‘Bridge Tanker’ programme,
which pits a modified variant of the MRTT,
known in the US as the LMXT, offered by
Lockheed Martin teamed with Airbus and
up against Boeing’s KC-46A Pegasus. KC-46 for the KC-Y project, under used for special missions.
A Request for Information (RFI) for which the USAF wants to procure another Ken Moss, LMXT campaign lead,
the KC-Y programme was released in 140-160 tankers. Under KC-X and KC-Y, Lockheed Martin Aeronautics told AIR
July 2021 and on September 17, 2021, the USAF plans to replace some 390 International that the reason for the huge
Lockheed Martin announced that it was ageing Stratotankers. Already more than size of the USAF tanker inventory is
offering the LMXT. Other contenders are 60 years old, the KC-135R/T is becoming because air refuelling “undergirds power
expected to be Embraer with its KC-390; increasingly difficult to sustain in service projection for the US Air Forces, US naval
Israel Aerospace Industries re-engineering and worsening availability issues could forces and fully enables most of our
second-hand B767-300 Multi-Mission impact military deployments worldwide. ground forces.”
Tanker Transport (MMTT) and other The USAF’s other tanker aircraft include He explained that the American way
smaller bespoke aircraft manufacturers. more than 55 KC-10A Extenders and of warfare is that the US “does not want
Boeing hopes to continue building the 50-plus MC-130H/J variants, the latter permanent presence abroad” and while

A KC-46A Pegasus aerial refuelling aircraft

connects with an F-15E Strike Eagle test aircraft
from Eglin Air Force Base, Florida in October 2018.
The 418th Flight Test Squadron is conducting
refuelling tests with the fighter at Edwards AFB in
California USAF

82 October 2022 AIR International

 KC-Z, but USAF leadership has talked
about the tanker potentially being a
smaller airframe, or a larger one, possibly
a wing-body design with stealth or
low-observable characteristics. The
KC-Z project is where the USAF
anticipates most new technologies and
designs to be implemented.
Meanwhile, a draft RFP for KC-Y is
expected in the first quarter of 2023,
with a final RFP in the second or third
quarter. Moss said that following the A3R
certification on MRTT that includes a
fly-by-wire boom and a rear vision system
“we think that opens up the door in the
very short, very near term of support of
the tanker by UAS along with LMXT’s
robust comms suite.”
He added: “It means that an LMXT with
all the gas it carries, might be able to drag
behind it a small squadron of unmanned
aerial refuelling aircraft and it has the
comms suite to support them. Some of
those could be armed or some could be
roled for ISR.”
However, recent developments have put
the KC-Y project in doubt. In April 2022,
Air Force Secretary Frank Kendall told the
House Armed Services Committee that a
competition might not go ahead although
there are some forces stations elsewhere, tanker requirements for KC-Y, the the USAF is still completing its analysis.
most are in the continental US with bidding companies will be offering new Then in June 2022, the Air Force Life
“the ability to project it in a short period technologies and systems on their Cycle Management Center released a
of time.” aircraft. The KC-Y project is known as the RFI for a new Advanced Aerial Refueling
He continued: “The only way that you are ‘Bridge Tanker’ because the aircraft will Family of Systems (AAR FoS) programme.
going to move that kind of manpower and become a ‘bridge’ between the current The RFI stated it wants to “identify
material quickly is through the air. And the generation of tankers delivered under technologies to develop, integrate, test,
only way that you can minimise that risk KC-X and the next generation tanker and field new capabilities into the current
is through capitalising air refuelling, to get to be procured under the future KC-Z and future tanker fleet” by integrating
those assets to where they need to be.” project – the third and final element of the them on the KC-46 and KC-135, “while
While the USAF is not expected USAF’s tanker re-capitalisation effort. developing the overall requirements for a
to include any major changes in its There are no requirements yet for new tanker aircraft.”

An artist’s impression of the LMXT using

the boom system to refuel an F-35A. A hose
and drogue system can refuel two aircraft
simultaneously, but the boom is more stable and
can transfer fuel more quickly Lockheed Martin

October 2022 AIR International 83

 Moss said that the AAR FoS is not a employment of an open architecture with depth perception.
threat to the KC-Y competition as the design with federated systems and data Other criticisms are that the boom is
RFI highlighted a number of capabilities streams. It offers alternative forms of also too stiff, there are issues with the
the USAF wants, so its current aircraft position, navigation and timing (PNT). It flight management system, fuel leaks as
are more adaptable and functional in the will also require tankers to have electronic well as cracks in drain and masts and
future, but it also indicated some of the warfare capabilities and integrate with tubes. These have limited use of the
operational concerns the USAF is trying autonomous systems. tanker’s full aerial refuelling capabilities.
to address that will also influence the If Kendall decides not to proceed with As a result, full-rate production of the
KC-Y development. KC-Y, this would be a considerable aircraft is being delayed until September
As an indication of the kinds of turnaround from when a Government 2024 – although by this time the majority
capabilities the USAF wants for its Audit Office (GAO) report, published of the 179 tankers will have been delivered
tanker fleet, the RFI stated: “Tankers in January 2022, highlighted seven – and overall, the KC-X programme is
must incorporate broad operational “critical defects” in the KC-46A. Two of suffering some $1bn in cost overruns.
enhancement and survivability these relate to the new remote vision Since 2020, Boeing has been developing
capabilities, such as connectivity/ system (RVS). In the KC-135 and KC-10 a new RVS 2.0 design and the GAO has
interoperability, real-time situational tankers the boom operators look through recommended that the USAF assess its
awareness (SA), and self-protection to a window to conduct the refuelling technology readiness levels, introduce a
meet future operational plan (OPLAN) and operation, but on the KC-46 the boom technology maturation plan and test the
National Military Strategy requirements.” operator uses RVS computer screen prototype in an operational environment.
This includes both line-of-sight and instead. The complaint about RVS is that However, the USAF has rejected these
beyond line-of-sight connectivity with the camera does not give a full view of recommendations stating that it is already
the future Joint All Domain Command the boom when it makes contact with a completing a thorough assessment
and Control (JADC2) environment and receiving aircraft. There are also issues that goes beyond that demanded by

KC-46A aircraft assigned to the

157th Air Refueling Wing perform
an elephant walk formation on the
runway at Pease Air National Guard
Base in September 2021 for the first
time since receiving the new airframes
US ANG

84 October 2022 AIR International

the current preliminary design review to Boeing, the KC-46A already provides changing anything about the boom or the
phase. It said that following the GAO data to the joint force, as well as fuel, external functionality of the airframe itself
recommendations would add to delays with secure voice and datalinks using that would impact certification.
when the KC-46A needs to be both line-of-sight communications and “This is a very low risk proposition for
introduced quickly. beyond line-of-sight communications and the US Air Force regarding its operational
In June 2022, the USAF’s Air Mobility SATCOM that can be integrated with an capability,” he added.
Command announced that KC-46A had Advanced Battle Management System. Sticking with the KC-46A means USAF
been approved to refuel 97% of aircraft must guarantee the maturity of the
types required. The Boeing spokesperson Future choices technologies and the success of the
said that the KC-46A “is flying hundreds The choice facing the USAF is whether proposed fixes. Opting for a new tanker
of sorties and delivering millions of to proceed with additional KC-46A would mitigate the risk of relying on a
pounds (lbs) of fuel every month. As of tankers instead of introducing a second, single tanker but would require separate
July 2022, it has delivered more than 84 different tanker aircraft under KC-Y. training and support arrangements.
million lbs of fuel globally and flown more The question is whether the risk of Whichever option is chosen the USAF
than 9,500 sorties.” remaining with the one tanker supplier urgently needs to sustain tanker numbers
Furthermore, RVS 2.0 is introducing outweighs the risk and cost of introducing as it retires more older aircraft.
new technologies that are hoped will lead a second platform. The Embraer spokesperson said: “For
to the autonomous refuelling of aircraft The Boeing spokesperson said: “Any the last 60-70 years, the ‘bigger is better’
in the future. It will allow the automatic potential competitors face the same concept has reigned worldwide. However,
identification of receiving aircraft and development and certification risk that the for tactical support operations, bigger
configuration of the refuelling system. KC-46 is now eliminating, at a cost which tankers may be unnecessarily costly. For
These are the kinds of technologies that they or the US taxpayer would bear.” those cases, smaller tankers can optimise
could be anticipated for KC-Z. According But Moss said that LMXT is “not the operation mission at its best.”

October 2022 AIR International 85

grow
Fit for

Among the measures designed to drive Embraer’s recovery is a 40%

reduction in production times All images Jorge Penalba unless stated

86 October 2022 AIR International

wth Jorge Penalba reflects
on Francisco Gomes
Neto’s turbulent first
years with Embraer,
and how the CEO
and his team intend to
steer the company into
calmer waters

H
ow do you rebuild your
life after being jilted at
the altar? That is just
one of the tasks faced
by Francisco Gomes
Neto, appointed CEO of
Embraer in April 2019.
“I’m not going to deny it, these three
years have been a very intense challenge.
Almost at the same time, [we faced] the
[COVID-19] pandemic and the breaking
of the agreement with Boeing.
“We spent two years preparing for
the merger with Boeing, separating
inventories, production lines, personnel,
offices... now we are experts in
disintegration and integration,” Neto
told AIR International.
“It was painful and expensive, very
expensive, but we are ready for the future.
We have designed a simpler, leaner, more
efficient organisation. Both operationally
and in terms of systems, we are much
better prepared.
”Hence our motto, ‘Fit for growth’.”

Ambitious plans
Embraer is 53 years old, has delivered
more than 8,000 aircraft to more than
100 countries, and every ten seconds
an Embraer takes off somewhere on the
planet. Neto and his senior management
are responsible for implementing a five-
year plan designed to improve revenues
and profitability.
The plan has five pillars: to increase
sales in all divisions; focus on efficiency;
develop agreements with strategic
partners to finance new developments;
innovation; and ESG (environmental,
social and governance) strategies.
All are governed by a shared mantra:
‘Safety first, quality always’. This cross-
company thinking is central to Embraer.

October 2022 AIR International 87

 “We will not be the biggest, but
we will be the most attractive”
Francisco Gomes Neto, Embraer

“There is only one Embraer, not five have to stockpile more raw materials to would have used more of that production
divisions. Our engineers now work for all ensure a smooth production flow,” said capacity, but the most important thing
divisions,” said Neto. “We want to use the Carlos García, Embraer’s VP finance. is that with the new owner we all win,
18,000 brains in the company, empower The five-year plan also involves reducing Embraer, Aernnova and the city of Évora.
employees and make them aware of the production times of all products by And we continue to have a presence in
economic results that are achieved with 40%. “For example, in landing gears we Portugal with Ogma.”
their efforts.” have cut [production time] by more than Embraer relies on innovation. In fact,
40% as well as in wings; in wiring we 40% of revenues in the last five years
Follow the money have reduced it by 17%. We are talking were generated by EmbraerX, the
According to Neto’s plan, the financial about manufacturing processes, about group’s US-based disruptive innovation
years 2021 and 2022 were Embraer’s synchronisation, for example, never about subsidiary. But there is also the new
‘recovery period’. Pandemic revenues fell reducing quality or safety”. urban mobility division, EVE. More than
by 30%, but last year they rose by 12% “In addition, this process of achieving ten start-ups collaborated in its creation
to $4.2bn in sales. This year Embraer greater efficiency and reducing production and the division has just launched as
expects an operating margin of 3.5-4.5% times will reduce capital costs by 40% and an independent company (although
and a return to profitability. While 2021- compensate for the increase in inflation, controlled by Embraer), listed on the New
2022 are expected to demonstrate the allowing us to maintain prices and become York Stock Exchange. A first round of
effectiveness of Neto’s plan, 2023-2026 more competitive,” García added. financing has raised $280m and the aim
will be, he said, “the time for profitable is to have an aircraft flying by 2026.
and sustainable growth”. “We want to Selling assets
benefit from the recovery of commercial Embraer has also sold assets, such as A reality check
aviation. We will not be the biggest, but its plant in Portugal’s Évora, which it Neto’s plan does not seem bad at first
we will be the most attractive.” sold to Aernnova this year. When asked sight. It includes financial wisdom,
There will be challenges, of course. if the break-up of the Boeing deal had process optimisation and efficiency,
“Right now, reducing inventory will not influenced the corporate governance, new products...
be easy because the global situation with decision, Neto but these are not normal times.
the war in Ukraine has made everything was elusive: Certainly not those enjoyed by
even more complicated. In fact, we “Obviously we Frederico Curado and Paulo
Cesar de Souza e Silva, Neto’s
predecessors at Embraer’s helm.
Embraer This Key bookazine
For a start, they were not competing
Brazil’s Aerospace Powerhouse will serve as a
with Airbus (Boeing having left the field
reference for
Fifty-two years in the aerospace business, of play by choice) and its A220. They
types such as the
Embraer is now the world’s third largest enjoyed a comfortable niche market
EMB 314 Super
producer of commercial aircraft. – regional jets, where Bombardier
Tucano, the EMB
Since the October 26, 1968, maiden flight eventually threw in the towel, swallowed
110 Bandeirante,
of the EMB 110 Bandeirante turboprop, up by the product development costs
Legacy executive
Embraer’s first aircraft type, the company that are now the biggest threat to the
jets, and the KC-
has developed, built, and sold everything Brazilians. So much so that the E2s have
390 airlifter.
from trainers, regional jets and airliners to yet to take off in sales and at the end of
military transports. April the A220 had a 532 order-strong
shop.keypublishing.com/
backlog, three times more than the E2.

88 October 2022 AIR International

Surprisingly, the E1 still has more pull than
the E2 – the first-generation E175 had
orders in April for 143 units, almost as
many as the E2.
The latter has not seen an acceleration
in demand after the pandemic, but the
opposite: four E2s were delivered in 2018,
14 in 2019, 11 in 2020 and 21 in 2021, but
only two this year.
The fact is that the E1 family is still too
young to need immediate replacement
in airline fleets, so it may take a while
for E2 sales to finally take off. Another
reason may be the failed merger of the
commercial division with Boeing: no
one is betting on a product that may
see changes soon. And then there is
the pandemic and the massive losses CLOCKWISE FROM TOP LEFT:
suffered by the Brazilian firm’s key airline Designed for single-pilot operations, the Phenom 100EV combines the performance of a jet with the operating
clients, among them Lufthansa and KLM. costs of a turboprop, according to its manufacturer Embraer
It’s the perfect storm.
Forty per cent of revenues in the last five years were generated by EmbraerX, the group’s disruptive innovation
Embraer has emerged from this storm subsidiary Embraer
more efficient, better prepared, but also
financially weakened. Embraer’s main production base is in São José dos Campos, São Paulo, Brazil. It also has sites in the State of
The decision to launch EVE as a São Paulo at Botucatu, Eugênio de Melo, and Gavião Peixoto Embraer
standalone publicly traded division
FAB’s reduced KC-390 order is in part compensated for by orders from overseas Embraer
enabled the group to raise the funding to
further develop and launch its eVTOL.
Something similar can be read
between the lines with the launch of the
new turboprop.

Not-quite-new launches
Although it has been on the drawing
board for two years, the last eight
months have seen the engines moved
to the rear of the aircraft. In another
update, the aircraft will feature
a traditional combustion engine,
already in existence but adapted to
a 90-seater. Alternative propulsion
methods have also been abandoned
– for now – and the new engine won’t
be an open fan. Putting the engines at
the back, however, means that in the
future Embraer will be able to opt for
alternative propulsion methods, such
as hydrogen, which needs more space
at the back for tanks, without having to
redesign the aircraft.
Alternatively, the group may simply lack
the capital to launch something new.
It’s very Embraer to be sensible and
thorough. As García said: “We don’t
promise what we can’t deliver.”
The decision to launch the E1 cargo
conversion this year was a wise one. The
increasing demand for freighters is here
to stay and there is a de facto niche in the
medium segment. It is likely that some
airlines will choose to convert their ageing
E1s into freighters and buy new E2s, so
Embraer could keep the E1 line active
while “backfilling” the E2 line.
For these two programmes, the turboprop
and the E1 freighters, Embraer has
launched a campaign to recruit 1,100
engineers this year, doubling its engineering
capacity. These additional engineers will
also be needed for Embraer’s other big bet:
the Energia family.

October 2022 AIR International 89

 “It was painful and
expensive, very
expensive, but we are
ready for the future”
Francisco Gomes Neto, Embraer

RIGHT:
CEO Francisco Gomes Neto joined Embraer in 2019
from Mann & Hummel

BOTTOM:
Author Jorge Penalba recently flew to Gavião Peixoto
Airport, owned and operated by Embraer, in an E2
Profit Hunter

Innovation and sustainability managers themselves recognise its margin of this division was 18% in the first
The Energia family consists of four unexpected success: after only five years quarter). However, Embraer does not rule
different aircraft of between nine and 50 and without even having flown, they have out entering this segment again.
seats. Some are more disruptive than accumulated more than 700 orders and
others, requiring different maturing of letters of intent. Turbulence in defence
existing technology, so that they will start Embraer’s military aviation operation is
with the Hybrid model but in a version Bizjet success finding it tough, not least due to the FAB
with a piston engine (more efficient in EVE’s success has been matched by (Força Aérea Brasileira, the Brazilian Air
cruise) assisted in the take-off phase by that of the Florida-based business jet Force) cutting its KC-390 order from 28
an electric motor (when more power is division. It expects to deliver between 100 to 22 units, then to just 15. In addition,
required). In a second phase, the piston and 110 aircraft by 2022 (the commercial Boeing’s commercial support for its
engine will be replaced by a hydrogen division expects to deliver between 60 export version, dubbed the Millennium, is
engine. The Hybrid is scheduled to fly and 70 units), bringing its backlog to no longer on the cards. All five models are
in 2030. The remaining three are planned two full years of production. Growth in being prepared for Portugal, which will
for 2035-2045. The Hybrid’s electric business jet sales is coming from the receive the first in 2023. It will be the first
motor will be developed in-house, base rather than the top tier. This means to be built in NATO configuration, which
making it Embraer’s first motor. Again, new and younger entrants are likely to may open up new sales when it enters
very Embraer, very cautious. enter with the Phenom and repeat the service in Europe and is joined by the two
With a view to overcoming this caution, brand when they need a higher capacity ordered by Hungary.
a group of Embraer executives went to or performance aircraft like the Praetor. Embraer is ‘in early talks with India’,
Silicon Valley where they met with start- According to Embraer, the Phenom is but its largest potential market, the US,
ups and swiftly concluded that they 35% of the light market and the Praetor which operates 56% of the medium
were “not taking high enough risks to 500 is the leader in mid-size fractionals. military transport aircraft fleet and was the
reach new markets with new products”, However, the top end of the executive target of the commercial partnership with
according to Daniel Moczydlower, CEO market has eluded the division. This Boeing, will have to be “restarted”. Another
of EmbraerX. explains why it has discontinued the potential customer is the Netherlands.
Founded as a direct result of this trip, Legacy (based on the ERJ) and Lineage “We are very well positioned and have
EmbraerX has since given rise to Beacon, 1000 (based on the E-Jets), concentrating announced publicly that we would
an innovative software in the form of an efforts on the more profitable and better manufacture in the country, in partnership
app for MROs, and EVE itself, whose accepted product lines (the operating with Fokker, and even integrate Dutch
products,” said Jackson Schneider, CEO
of Embraer Defesa & Segurança.
Schneider is optimistic that Embraer
“will soon announce new sales of the
KC-390”, partly because of the big push
defence products are experiencing with
the war in Ukraine. “During the two years
of the pandemic nothing moved, but now
we are getting requests from countries
we didn’t even have on our radar,” he
said. “We can deliver aircraft right now
and that’s a great opportunity.”
Another important project that will soon
take off is the final assembly of the Gripen
for the FAB. Two aircraft are currently in
Gavião for certification testing and final
assembly of the first Brazilian units is
scheduled to begin in 2023.

90 October 2022 AIR International

 Specialists in Regional Aircraft
Marketing ~ Sourcing ~ Lease Management
Tel. + 44 1753 832088 [email protected]

Serving the regional airline

community for over 25 years
We have extensive experience in the Embraer
market and are offering a number of ERJ 135/145s
and EJets for sale.
Visit our website for our latest portfolio.

www.skyworld.co.uk

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Russo-Indian Billed as the first ever
operational supersonic
cruise missile, the
heavyweight, sea-
skimming PJ-10
BrahMos is set to be
developed into a more
versatile and lethal
version. Alexander
Mladenov reports

A Brahmos-ER launch at Chandipur on January 20,

2022 Indian MOD

92 October 2022 AIR International

Delight
BrahMos missile explained
The two-stage missile with low radar signature
uses a solid-propellant booster as its first stage
to reach supersonic speed before separation. The
second stage is an air-breathing liquid-fuel ramjet
accelerating the missile up to Mach 2.8 in the
cruise flight phase (cruise speed varies between
Mach 2 and 2.8 depending on the altitude).
This, in turn, results in quick engagement time
and a good degree of survivability when facing
nown as the most and the land-launched version of the

K
modern air defences due to its missile-avoidance
successful ever Russo- missile was additionally exported to Syria manoeuvring capability. Moreover, the overall
Indian defence joint- and Vietnam. destructive effect is enhanced thanks to the large
venture defence, The improved Onyx derivative with a kinetic energy on impact in steep dive.
BrahMos Aerospace substantial Indian-made content, was The propulsion technology is borrowed from
is up and running to set to be developed in sea-, air- and the Onyx missile unchanged, while the guidance
supply supersonic cruise land-launched versions by BrahMos system has been developed by BrahMos
missiles to the three major Indian military Aerospace. Now, 24 years later, the Aerospace. In the beginning of production, the
branches and is also set to begin the joint-venture company has turned into missile had some 65% share of Russian-supplied
first export deliveries of its high-tech a multibillion-dollar business with bright components, including the propulsion and the
weapons system. At the same time, prospects and it is set to further grow radar seeker. Later, the Indian content increased to
the joint venture company intends to for at least two more decades, rolling 65%, including a radar seeker and rocket booster.
launch the development of two new- out much-improved missiles for a vastly The baseline PJ-10 version uses inertial
generation air-launched missiles derived expanded range of launch platforms, navigation with satellite correction (INS/GPS);
from the baseline BrahMos design in the such as the BrahMos NG version and a the satellite navigation utilises input from
foreseeable future . new derivative with radically improved Indian, Russian and US navigation satellites. The
supersonic missile flies at up to 40,000ft cruise
The BrahMos was developed by using flight performance and lethality, the
altitude while terminal altitude can be as low
the baseline design of the Russian- hypersonic-speed BrahMos II.
as 33ft. The missile can follow a low-altitude
made P-800 Onyx (NATO name SS-N-
or combine trajectory, with high-altitude cruise
26 Strobile) missile, offered for export Big business flight for longest range and terminal phase in the
under the new name Yakhont. This novel As of mid-2022, Atul Dinkar Rane, chief sea-skimming mode. The active radar seeker has
trisonic ship – or land-launched cruise executive officer and managing director of a 43nm maximum range, reported for the Russian-
missile was developed and tested in the joint-venture company, said that the made design, and it is believed that the improved
the late 1980s and the early 1990s by total BrahMos orders amounted to $6bn Indian-made seeker design has comparable
Russian company NPO Mashinostroenia, and it is expected to grow to $13bn. performance while also boasting much better
now a subsidiary of Tactical Missiles Formed in February 1998, BrahMos target discrimination capability.
Corporation, the Russian holding Aerospace combines India’s Defence Initially, the missile’s range was capped at
company controlling most of the design Research and Development Organisation 157nm due to the restrictions imposed by
bureaus and production plants involved in (DRDO), holding 50.50% of the the MTCR, but following India’s entry into the
the production of air- and sea-launched company’s shares, with Russia’s NPO multilateral export control regime, the range was
weaponry. Its fielding in Russian Navy Mashinostroenia having 49.50%. The set for extension initially to 243nm and at a later
service took place from the early 2010s company name is derived from two stage it could reach 324nm.
The missile, featuring clipped-tip delta wings
at mid-fuselage and four smaller delta control
surfaces at the rear, is 8.55m long and 0.65m in
diameter and comes fitted with a high-explosive
or submunition warhead. The former weights 441
to 661lb and is of the semi-armour piercing type,
while the latter weights 551lb.
First test firing took place from a land-based
vertical launch platform on June 12, 2001, and
a ship-based launch followed on December 18,
2008, from Rajput-class destroyer, INS Ranvir.
The submarine-launched version saw its maiden
launch on March 20, 2013.

The BrahMos-A seen here during its separation

sequence when launched from a Su-30MKI.
Following a gravity fall of between 330ft and
490ft, the booster fires up
to accelerate the mission to supersonic speed
All images BrahMos Aerospace unless stated
BrahMos-A separation from the Su-30MKI as seen from a rear-mounted camera

October 2022 AIR International 93

 THIS IMAGE: Indian Air Force Su-30MKI carying a
BrahMos-A Indian Air Force

BELOW: Brahmos had a massive stand at the ARMY

2022 exhibition in Moscow during August. The
company has come a long way over the past 20
years or so. Giovanni Colla

94 October 2022 AIR International

 prominent rivers – Brahmaputra of India
The test launch of a BrahMos and Moskva of Russia.
missile from a ground pad The sea-launched BrahMos version
at the Integrated Test Range
was inducted into regular service with
at Chandipur in India on
September 30, 2019 the Indian Navy in 2005 and the land-
Indian MoD launched derivative followed suit in
2007. As of July 2022, Rane said that
there were 30 to 35 test and evaluation
launches for the various BrahMos
derivatives, while the Indian military has
also amassed 65 more launches, with
only two of these being classified
as unsuccessful.
The land-launched BrahMos version,
as Rane revealed, currently equips four
regiments (the first of these was inducted
in 2007 with 67 missiles, five mobile
autonomous launchers and two mobile
command posts), with plans for ordering
missiles and launchers for another one.
The sea-launched BrahMos derivative
(offered in both the inclined- and
vertical-launch configurations) is also in
widespread use, and is the main weapon
arming all newly built or upgraded major
Indian Navy warships and is used to
knock out sea and land targets.
There are three blocks of the BrahMos in
service from land platforms. Block I is the
initial anti-ship and land-attack standard
fielded in 2007, while Block II is an
improved land-attack standard, endowed
with steep-dive and target discrimination
capability, which was tested for the first
time in 2009. In turn, the Block III, first
tested in 2013, is a further improved land-
attack standard, with mountain warfare
capabilities thanks to the new guidance
system incorporating large-scale
manoeuvrers and steep-dive capability at
high altitude, coupled with precise strike
capability. In March 2018, the missile
was tested for the first time with an
indigenously designed radar seeker.

Export ambitions
In January 2022, the Philippines became
the launch export customer for the
Russo-Indian supersonic cruise missile,
to be used for coastal defence. The
order covers the delivery of three coastal
batteries, each with two launchers and
an undisclosed number of missiles to
equip a Marine Corps Shore-Based Anti-
Ship Missile Battalion, at a total price of
nearly $375m, with first deliveries slated
for 2023. The Philippines purchase of
the BrahMos is a countermeasure to
the People’s Liberation Army Navy’s
aggressive expansion in the region in
recent years, including the establishment
of control over many islets.
Further sales prospects for the missile,
said Rane, include three or four countries
in Southeast Asia – such as Vietnam,
Malaysia, Myanmar, and Indonesia – in
addition to several customer nations in the
Middle East, with the total export orders
expected to hit $3bn.
Rane has also shared that he has hopes
to eventually sell the BrahMoS missile

October 2022 AIR International 95

 to the Russian Ministry of Defence.
The missile is considered only partially
made from foreign components and as
such it could be considered suitable for
equipping weapons platforms operated
by the Russian military.
“At every meeting of BrahMos
shareholders, at every meeting of the
supervisory board and board meeting,
this question is being raised: when an
order for BrahMos missiles will be placed
from the Russian side? The company
wants to sell. The missile should be in
service with the Russian Armed Forces.
But this should be a political decision. We
are waiting for it,” Rane told Russian news
agency TASS.

Air-launched BrahMos-A
Compared to the land- and sea-launched
versions, the BrahMos-A derivative The ship-launched BrahMos version was fielded in service as early as in 2005
features a reduced launch weight of
2,550kg vs 3,000kg for the land-launched structural modifications to carry the large-scale production, happened on
BrahMos derivative, and comes powered bulky and heavyweight missile on a December 8, 2021, with the IAF declaring
by a smaller rocket booster to reduce pylon between the engine trunks. The that the integration works had been
length. The list of its unique design works, however, saw a serious delay and completed in a successful manner. The
features includes fins added to improve as a result the first BrahMos-capable Indian MoD stated that the BrahMos-A
after-launch stability and a redesigned Su-30MKI was not handed over to the provides the IAF with much-desired
nose cap. Its launch envelope is from Indian Air Force (IAF) until 2015. capability to deliver strikes from extended
1,640 to 40,000ft and cruise altitude is In contrast to the land- and sea- stand-off ranges on sea and land targets
40,000ft. The missile is gravity-separated launched versions, the BrahMos-A saw with pinpoint accuracy, round the clock, in
from the Su-30MKI, with free-fall of 330 a notably protracted development and all weathers. The new missile, combined
to 490ft and then the detachable booster testing programme. Captive-carry tests with the Su-30MKI long-range fighter
fires up for initial acceleration, while the using two specially modified Su-30MKIs (with unrefuelled combat radius of 810nm,
nose cap is also jettisoned. commenced in 2016 and the first test gives the IAF a strategic reach.
Procurement of as many as 200 launch was reported on November 22, In October 2020, the IAF conducted the
BrahMos-As was cleared by the Indian 2017, aimed at a sea target in the Bay of longest-range BrahMos-A strike mission,
Cabinet Committee on Security in Bengal and scoring a direct hit. The IAF which saw a Su-30MKI taking off from
October 2012, at a cost, equating to proudly reported at the time that it had a Punjab air base in India to attack a
$1bn in 2020. This budget also covered become the first air arm in the world to sea target that was 2,160nm away in the
the costs associated with the missile have successfully tested such a missile Indian Ocean. The mission was flown
integration and testing activities. At the on a sea-based target; the official Indian with in-flight refuelling to demonstrate
time, the first launch was optimistically MoD press-release also maintained that the strategic reach of the newly inducted
scheduled for December 2012. the missile range was close to 162nm. weapons system.
The modifications undertaken on The second test launch was directed On May 12, 2022, a Su-30MKI made the
the Su-30MKI to be used as a launch against a land target and occurred on first successful launch of the extended-
platform for the BrahMos-A involved a May 19, 2019. The last BrahMos-A test range BrahMos-ER version (until then
strengthened undercarriage and airframe launch, before clearing the missile for tested from a land-based launcher), which

The naval version of the BrahMos seen being fired from INS
‘Chennai’ during the TROPEX exercise in 2017 Indian Navy

96 October 2022 AIR International

scored a hit on its designated target in
the Bay of Bengal.
On January 20, 2020, the IAF stood up
its first Su-30MKI-equipped squadron,
capable to use the BrahMos-A. Known
as the ‘Tigersharks’ and stationed at the
Thanjavur air force station in Tamil Nadu
in South India, it was slated to get its full
strength-fleet of 18 aircraft in 2021. Eight
of these heavyweight twin-engine fighters
are configured to carry the BrahMos-A.
The Thanjavur-based Su-30MKI
squadron is seen by the Indian military
command as a game-changer in the
strategically important Indian Ocean
Region (IOR), which has seen a growing
Chinese presence in recent years.
The IAF plans call for fielding of an
eventual fleet of 40 to 50 BrahMos-
capable Su-30MKIs.
The BrahMos-A is seen here in its launch configuration complete with a nose cap and additional fins on the
booster for better post-launch stability Alexander Mladenov
New generation in
the pipeline cruise missile, which is to be fielded in
The BrahMos-NG is a scaled-down regular service in late 2022.
air-launched cruise missile, two times
lighter than the baseline Brahmos-A Cost considerations
and much smaller, enabling it to be more As Rane said in his interview to the TASS
versatile and flexible. Its launch weight news agency, the BrahMos II testing
is 2,865lb, the warhead is 441lb, the could begin in five to six years. The price
length is about 5m and the diameter is of the missile, however, is expected to
0.5m in an effort to allow the supersonic be ‘excessively high’ and that is why the
cruise missile to be carried by a wide BrahMos II will not be offered for export.
variety of tactical jets. In addition, India is a member state of
At a later stage, it could be also modified the Missile Technology Control Regime
for use by sea platforms. (MTCR), allowing it to develop missiles
The new missile with 157nm range is with more than 300km maximum range
slated to be included in the arsenals of and weight exceeding 500kg, but without
the IAF Su-30MKI, which can carry up permission to transfer these technologies
to five (four under the wings and one to third parties. The BrahMos II’s cruise
under the fuselage), compared to only speed will be up to Mach 8, range will
one BrahMos-A in addition to the MiG- exceed 324nm and the size will allow its
29UPG/K/KUB and Tejas (each of these external carriage by the Su-30MKI.
types being capable of carrying two
missiles). In general, as Rane said, the LEFT: A vertical launcher for the BrahMos fielded
new missile could be integrated on any in service with the Indian Army. This is a mobile
modern tactical fighter jet. autonomous launcher based on a 12x12 TATRA truck,
The list of the new technologies to be capable of carrying three missiles DRDO
used in the BrahMos-NG includes a
digitised fuel injection system to increase BELOW:
An artist impression of the BrahMos missile in cruise
thrust and its top speed will hit Mach configuration showing the nose intake and the cone
3.5. An air-to-air version is also under housing the active radar seeker
consideration, to be used against slow-
speed targets over extended ranges,
deep inside enemy airspace.
According to Rane, the BrahMos-
NG design, developmental and testing
activities are expected to cost between
$250m and $300m. He has predicted
that the flight testing could commence
in two and a half to three years after
financing is secured, while the production
launch is expected in five years from the
go-ahead date.
The BrahMos II is a hypersonic
derivative, with cruise speed exceeding
Mach 5, intended to be developed as
a follow-on of the baseline BrahMos,
powered by an air-breathing scramjet
engine. It will rely on newly transferred
Russian missile technologies proven on
its 3M22 Tsirkon sea-launched hypersonic

October 2022 AIR International 97

 LAST
LOOK
Boeing has delivered its first satellites
since the pandemic, two lightweight
702SP satellites ordered by content
connectivity service provider SES Boeing

98 October 2022 AIR International

 NEXT
MONTH
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Air Nostrum Group has reserved ten Airlander 10 aircraft, for operations on regional routes HAV

AVIATION SAFETY The Team

Crashes may grab the headlines, but we look at Tara Craig Editor
the tech that’s going to keep us safe in the air Gordon Smith Editor at Large, Commercial Aviation
Thomas Lee Assistant Editor, Commercial Aviation
Mark Broadbent Contributing Editor
Simon Lee Editor, Modern Military
IRAN’S AN-140 REBIRTH Alan Warnes Group Editor at Large, Modern Military
Khalem Chapman Deputy Editor, Modern Military
Eight years of work paid off when Iran unveiled Josef Campion Assistant Editor, Modern Military
its first IrAn-140T prototype in May. We detail this Dave Allport News Editor, Modern Military
new light military transport and its applications
Debbie Walker, Andy O’Neil, Molly Eastwood, Tracey Croft,
Dan Jarman & Dave Robinson Design
Steve Donovan Head of Design
The first IrAn-140T Simorgh prototype Ali Naderi
David Taylor Group Production Editor
INSIDE EMIRATES Sally Hooton, Suzanne Roberts, Sue Rylance
Airline president Sir Tim Clark looks back at Production Editors
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Belgium’s No 20 Squadron as it prepares to reach Karen Bean Head of Operations and eCommerce
full operational capability with the A400M Atlas Peter Edwards Head of Finance
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