Vertical Aerospace has started integration testing for its next-generation hybrid-electric propulsion system and produced the first all-electric Valo battery from its upgraded assembly line, advancing the company’s certification and future production plans.

The milestones support Vertical’s propulsion and energy systems roadmap for both the all-electric Valo aircraft and future hybrid-electric variants designed for extended-range operations.

Stuart Simpson, CEO of Vertical Aerospace, says: “Hybrid capability complements our all-electric Valo platform and unlocks a broader range of civil and defence applications. At the same time, advancing our battery technology and manufacturing capability is critical to certification and scaling production. Together, these milestones demonstrate the strength and breadth of our technology platform.”

The company’s hybrid-electric propulsion system has entered testing on the Hybrid Propulsion Evaluation Rig (HYPER) at its flight test centre at Cotswold Airport following more than two years of development work at the Vertical Energy Centre.

The facility enables integration and validation of the turbine, generator and associated electrical systems, while also allowing engineers to test software, control architecture, system response and fault scenarios before ground and flight trials.

Vertical is working with several partners on integration of a sustainable aviation fuel-compatible gas turbine and electric generator, while internally leading software and systems integration development.

The resulting turbogenerator will be integrated into a prototype hybrid-electric Valo aircraft for future flight testing and demonstrations. Vertical says the hybrid-electric variant is expected to significantly expand aircraft range, payload and operational flexibility.

The company is targeting certification of the hybrid-electric aircraft with the Civil Aviation Authority and European Union Aviation Safety Agency.

Separately, Vertical has produced the first battery on its upgraded assembly line at the Vertical Energy Centre. The 15,000 sq ft facility, which has supplied battery systems for piloted flight testing since 2024, now includes automated aerospace-grade manufacturing processes intended to improve efficiency, consistency and production scalability.

Battery packs produced on the line will support certification aircraft and initial production capacity ahead of service entry, while prototypes undergo environmental and operational testing.