Heart Aerospace unveils full-scale 30-seat hybrid-electric aircraft demonstrator

Swedish hybrid-electric airplane maker Heart Aerospace has unveiled its first full-scale demonstrator, the Heart Experimental 1 (Heart X1), which will serve as a platform for the testing and development of the company’s regional 30-passenger ES-30 aircraft. Initially, the 32-metre wingspan X1 will be used for ground-based testing, focusing on charging operations, taxiing and turnaround procedures, with a fully electric first flight planned in Q2 2025. A pre-production X2 prototype is the next step to further mature the design and production methods, with a hybrid-electric flight scheduled for 2026. Heart has also announced other ES-30 developments that include completion of ground support tests with Braathens Regional Airlines, SAS and Swedavia, plus the addition of Malaysia-based AirAsia to its Industry Advisory Board. Meanwhile, UK-based Gen Phoenix has partnered with DOY Design to supply lightweight leather for the X1 passenger seats.

The X1 demonstrator was built almost entirely in-house at Heart’s Gothenburg facilities and reflects a strategy to develop both the design and production processes simultaneously, explained the company.

“We need to develop new methods to get net zero aerospace technologies to market faster,” said Anders Forslund, co-founder and CEO. “It is a testament to the ingenuity and dedication of our team that we’re able to roll out a 30-seat aircraft demonstrator with a brand-new propulsion system, largely in-house, in less than two years.”

In preparation for the first flight, Heart will test critical systems over the coming months by running hardware tests both on and off the airplane. The hybrid-electric X2 will demonstrate the company’s Independent Hybrid propulsion system. Heart is also to establish a pilot manufacturing plant to accelerate pototyping towards the manufacture of a fully conforming aircraft, with type certification of the ES-30 targeted by the end of the decade.

The electric zero-emission version will have a range of 200 kilometres, a hybrid-electric range of 400 kilometres and an extended range of up to 800 kilometres with 25 passengers. To date, Heart says it has 250 firm orders for the ES-30, with options and purchase rights for an additional 120 planes, and letters of intent for 191 more aircraft.

The ground support procedure tests carried out in collaboration with Braathens Regional Airlines, SAS and airport operator Swedavia, were conducted as part of the Swedish research project ELISE, which brings together technology companies with airlines and airports to foster the development of electric aviation infrastructure in the country.

The procedures tested at Säve Airport in Gothenburg included verification and testing of the charging procedure; evaluation of charging routines; onboarding and offboarding procedures for passengers and cargo; and ground support experience and maintenance routines.

The company has filed two EU design applications and one patent application for a new nacelle integration design that Heart says will significantly improve the flight characteristics of the ES-30, allowing it to operate on shorter runways. Manufactured in-house using automated composite technology, the design, in which the nacelle is centred on the wing, will be incorporated on the X2. By minimising the aerodynamic interference between the nacelle and the wing, it allows for a higher angle of attack and delaying stall. This improves lift generation during both cruise and landing phases, giving the ES-30 the ability to fly at lower speeds with greater aerodynamic efficiency.

“The operation of electric airplanes requires highly efficient aerodynamic designs and our research on propulsion integration centred on the wing has led to a concept that significantly outperforms conventional designs,” said Alain Cuenca, Senior Aerodynamics & Thermodynamics Engineer at Heart Aerospace.

Added Ben Stabler, Chief Technology Officer: “Developing innovative net zero aerospace technologies demands a revolution in product development and manufacturing, much like what we’ve witnessed in the automotive and space industries.”

Development of the X1 has been funded in part by grants provided by the Swedish innovation agency Vinnova. In August, Heart was selected for a $4.1 million grant by the FAA’s Fuelling Aviation’s Sustainable Transition (FAST) programme to develop the X2’s management system for the hybrid-electric propulsion.

New Industry Advisory Board member AirAsia aims to make air travel more accessible across the SE Asia region and to serve “underserved” communities, and has a long-term goal to cut its net CO2 emissions to 50% of 2005 levels by 2050.

“At AirAsia, we are committed to exploring new technologies that align with our focus on operational efficiency and sustainability,” said Capt Chester Voo, the group’s Deputy COO, Airline Operations. “While electric and hybrid-electric aircraft are still nascent in Asia, they represent a compelling future for sustainable air travel. We look forward to contributing our aviation experience and insights from this dynamic region to Heart Aerospace’s pioneering work.”

In collaboration with DOY Design, Gen Phoenix has supplied its recycled low-carbon leather product Essence to upholster the 30 passenger seats in X1. It offers an 83% lower carbon footprint than traditional leather “while maintaining the premium qualities of fine upholstery,” says Gen Phoenix. DOY Design’s Ultra-Slim seats used by Heart on the demonstrator have a thin structure and higher light levels.

“Our mission is to reduce our impact on the environment by adopting sustainable design practices and using materials like Essence, which offer both sustainability and quality,” said Gary Doy of DOY Design, whose seats recently received a Red Cabin Trinity Award for Best Sustainability Concept.

Top photo: The Heart Aerospace X1 demonstrator

Bottom photo: Interior of X1 with DOY Design seats upholstered with Gen Phoenix’s Essence leather

Christopher Surgenor

Editor

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