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VoltAero has successfully flown its hybrid-electric Cassio&nbsp;testbed using 100 percent sustainable aviation fuel (SAF) provided by TotalEnergies, the French start-up announced on September 21. According to the French start-up, this was the first time any aircraft with a hybrid-electric powertrain has flown on pure SAF, a biofuel that is typically blended with traditional jet fuel.&nbsp;
The company’s Cassio technology demonstrator, a modified Cessna 337 Skymaster, took off from VoltAero’s development facility in Royan, France on September 8. It was filled with TotalEnergies’ Excellium Racing 100, a biofuel made from winemaking waste collected in French vineyards, according to VoltAero. The same fuel has been used in automobile races since 2022 and reduces carbon dioxide emissions by at least 65 percent over its entire life cycle when compared with fossil fuel equivalents.
The flight&nbsp;lasted just over one hour, a&nbsp;company spokesperson told&nbsp;AIN. Before the flight, VoltAero tested the fuel on its ground test bench for more than three hours, they said. VoltAero would not disclose the cost of the fuel it acquired from TotalEnergies.
“Based on initial results, we calculated a truly impressive CO2 reduction of approximately 80 percent while operating the Cassio powertrain in its electric-hybrid mode and with the internal combustion engine fueled by TotalEnergies’ Excellium Racing 100,” said Jean Botti, VoltAero’s CEO and chief technology officer. “It underscores the opportunity for production Cassio aircraft to represent a major step closer to aviation’s decarbonization goals by replacing standard Avgas 100 high-octane fuel for aviation piston engines.”
While VoltAero’s hybrid-electric aircraft can operate solely on battery power during all phases of flight (taxi, takeoff, landing, and cruise), it has combustion engines that function as a range extender, recharging the batteries in flight. For short flights of up to 150 kilometers (90 miles), the aircraft does not require any fuel at all. In addition to enabling longer flights, the hybrid system can provide backup power if there’s a problem with the electric propulsion system.&nbsp;&nbsp;
VoltAero has been <a href="https://futureflight.aero/news-article/2020-10-14/voltaeros-hybrid-propulsion-system-makes-first-flight-cassio-demonstrator">flying its Cassio testbed</a> since 2020, but this was the first time it flew using biofuels or SAF. The SAF that is commercially available today is limited to a maximum blend of 50 percent biofuel, but aircraft OEMs have been flying various aircraft on pure SAF experimentally for years. For example, Boeing’s EcoDemonstrator made the world's first commercial airplane flight using 100 percent SAF in 2018.&nbsp;
TotalEnergies’ unblended SAF has also been used to power <a href="https://www.ainonline.com/aviation-news/air-transport/2021-10-29/french-partners-fly-a319neo-using-100-percent-saf">an Airbus A319neo</a> test aircraft as well as <a href="https://www.ainonline.com/aviation-news/business-aviation/2021-11-09/airbus-h225-flies-100-percent-saf">an Airbus H225</a>, which became the first helicopter to fly using 100 percent SAF in 2021. The company’s blended fuels have been available at Paris-Le Bourget, Clermont-Ferrand, and Bordeaux-Mérignac airports.&nbsp;
“This demonstration flight is part of our commitment to support players in the aviation sector for their decarbonization objectives,” said Joël Navaron, the President of TotalEnergies Aviation. “More broadly, it demonstrates our desire to continue our research and development efforts to offer an alternative to aviation gasoline containing lead, thereby meeting the challenges of general aviation’s decarbonization. We already have initiated several actions—such as the installation of several electric charging stations for general aviation aircraft, and the launch of a pilot program aimed at offering SP98-type fuel for compatible aircraft.”
VoltAero’s plans for decarbonizing aviation include a whole family of hybrid-electric Cassio aircraft and possibly even hydrogen-powered aircraft. Its first product will be the Cassio 330, a five-seat aircraft equipped with a four-cylinder, 165-kilowatt Kawasaki engine and <a href="https://www.futureflight.aero/news-article/2022-07-22/voltaero-partners-safran-and-thales-its-cassio-hybrid-electric-aircraft">Safran’s EngineUs 100</a> smart electric motor. The company revealed its <a href="https://futureflight.aero/news-article/2023-06-19/voltaero-unveils-first-cassio-330-prototype-aircraft-ahead-first-flight">Cassio 330 prototype at the Paris Airshow</a> in June 2023 and intends to begin flight testing with it in 2024.&nbsp;
Subsequent Cassio models will include the six-seat Cassio 480 and the 12-seat Cassio 600. The Cassio 480 will use a six-cylinder thermal engine provided by Kawasaki. VoltAero has not yet announced which engine will power the larger, 600-kilowatt Cassio 600.

Science & Technology Editor

Hanneke Weitering

VoltAero Flies Hybrid-electric Aircraft on Sustainable Aviation Fuel

VoltAero is debuting the first full-scale prototype of its Cassio 330 hybrid-electric aircraft at the Paris Airshow this week. The Cassio 330, which can be configured&nbsp;with either four or five seats, will be the first of three hybrid-electric aircraft that VoltAero intends to produce for cargo, air taxi, and medevac applications.&nbsp;
The French start-up plans to begin flight testing with the newly revealed Cassio 330 prototype later this year. For the upcoming flight test campaign, VoltAero will equip the aircraft with a four-cylinder, 165-kilowatt engine supplied by company partner and&nbsp;<a href="https://www.ainonline.com/aviation-news/business-aviation/2023-05-25/voltaero-wins-kawasaki-funding-hybrid-electric-aircraft">strategic investor Kawasaki Motors</a>, a company best known for its motorcycle engine products.&nbsp;
VoltAero expects a&nbsp;second Cassio 330 prototype, which the company will use for its airworthiness certification program, to take flight in the second quarter of 2024. That version will become the first to fly using VoltAero’s new hybrid-electric propulsion system, which consists of Kawasaki’s four-cylinder thermal engine and&nbsp;<a href="https://www.futureflight.aero/news-article/2022-07-22/voltaero-partners-safran-and-thales-its-cassio-hybrid-electric-aircraft">Safran’s EngineUs 100</a>&nbsp;smart electric motor.
<h3 class="subheading">Avidyne's Quantum Avionics Selected For Cassio Flight Deck</h3>
The second Cassio 330 prototype will also come equipped with&nbsp;<a href="https://www.ainonline.com/aviation-news/advanced-air-mobility/2023-06-08/avidyne-introduces-quantum-avionics-platform">Avidyne's new Quantum avionics platform</a>. The full interior of the five-seat Cassio 330 model, including the new avionics suite,&nbsp;is on display at the Paris Airshow this week.
Subsequent Cassio models will include the six-seat Cassio 480 and the 12-seat Cassio 600. The Cassio 480, which will produce a combined hybrid-electric propulsion power of 480 kilowatts, will use a six-cylinder thermal engine also provided by Kawasaki. VoltAero has not yet announced which engine will power the larger, 600-kilowatt Cassio 600.&nbsp;
VoltAero has partnered with French company Akira Technologies&nbsp;for the integration and validation of Cassio’s hybrid propulsion unit, including the engine and motors. Akira Technologies&nbsp;will also take responsibility for the&nbsp;design, development, and ground testing of the gearbox, according to VoltAero.
Each of the Cassio aircraft will use only electric power during taxi, takeoff, and landing, while the hybrid engine feature will activate during cruise flight to function as a range extender that recharges the batteries. The hybrid system also serves as a backup in case of a problem with the electric propulsion. VoltAero says its aircraft will be able to operate on sustainable biofuels as well as hydrogen power in the future.

VoltAero Unveils First Cassio 330 Prototype Aircraft Ahead of First Flight

The French government is backing VoltAero’s work on the Cassio family of hybrid-electric aircraft with a €5.6 million ($6 million) grant. The funding, announced on June 8, is part of the country’s France 2030 investment fund and was awarded by BPI France, the agency tasked with fueling economic growth by backing entrepreneurs.
VoltAero’s propulsion system is based on electric motors installed in the aft fuselage that will be used for all-electric power during taxi and takeoff, as well as during cruise flight on short trips of less than 150 kilometers&nbsp;(94 miles). An internal combustion engine provides supplementary power to extend range, while also recharging the batteries during flights.
In May, Kawasaki Motors announced that it is backing VoltAero’s Series B funding round with a&nbsp;strategic investment of an undisclosed amount and the offer of engine expertise. The new capital builds on a&nbsp;<a href="https://www.futureflight.aero/news-article/2022-11-02/voltaero-secures-eu32-million-and-production-partner-hybrid-electric-cassio">€32 million investment</a> by Italy's TESI group in November 2022.
“This [BPI France] grant is another important vote of confidence in VoltAero and our vision to develop the unique family of Cassio electric-hybrid general aviation airplanes for safe, quiet, efficient, and eco-friendly flight,” said VoltAero CEO and chief technology officer Jean Botti. “It contributes to the Cassio 330’s development, certification, and production.”
VoltAero will be exhibiting at the Paris Air Show later this month and said it will provide a further program update during that event. As it continues development work behind the scenes, the company has been attracting provisional sales commitments from prospective operators, such as fractional ownership group Sky2Share, which on May 23 announced it has placed preorders for 15 of the five-seat Cassio 330 model. The agreement takes the number of provisional sales commitments booked by VoltAero to 218, including both orders and options.
<h3 class="subheading">Aerospace Groups Safran and Thales Are Cassio Program Partners</h3>
Featuring a forward fixed canard and aft-set wings with twin booms supporting a T-tail horizontal stabilizer, the Cassio will use <a href="https://www.futureflight.aero/news-article/2022-07-22/voltaero-partners-safran-and-thales-its-cassio-hybrid-electric-aircraft">Safran's EngineUs</a> electric motors in the aft fuselage-mounted propulsion system for all-electric power during taxi, takeoff, and landing. The hybrid feature—with an internal combustion engine—comes into play as a range extender, recharging the batteries in flight. The hybrid element also serves as a backup in case&nbsp;of a problem with the electric propulsion.
Another major French aerospace group,<a href="https://www.futureflight.aero/news-article/2022-07-22/voltaero-partners-safran-and-thales-its-cassio-hybrid-electric-aircraft"> Thales, is a program partner</a>, providing its FlytLink Edge computing system. This technology is already being employed to process multiple data streams on VoltAero's Cassio 1 technology demonstrator aircraft, using inputs from onboard cameras and sensors.
Cassio plans to offer three versions of the aircraft, each sharing a high degree of modularity and commonality. The company’s use case targets regional commercial operators, air taxi/charter companies, private owners, and utility-category services for cargo, postal delivery, and medevac applications.
Plans call for the five-seat Cassio 330, powered by the 330-kilowatt electric-hybrid propulsion system, to come first. VoltAero’s follow-on six-seat Cassio 480 would generate electric-hybrid propulsion power of 480 kilowatts, while the 12-seat Cassio 600 would feature useful power of 600 kilowatts.
The aircraft will be certified under EASA's CS23 certification specifications for single-engine, general aviation aircraft. Each Cassio aircraft will have a range of about 800 miles (1,300 kilometers) and a cruise speed of around 230 mph (370 km/h).&nbsp; The all-electric range would be less than 94 miles (150 kilometers).&nbsp;
Headquartered at the Aérodrome de Royan-Médis in southwest France, Cassio plans to start final assembly in a purpose-built facility at the Rochefort Charente-Maritime Airport in France’s Nouvelle-Aquitaine region.
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Managing Editor

Charles Alcock

French Government Backs VoltAero's Hybrid-Electric Cassio Aircraft with €5.6 Million Grant

Kawasaki Motors has become a strategic investor in VoltAero, joining Series B funding for the development, production, and certification of VoltAero’s Cassio electric-hybrid aircraft family. The companies revealed the undisclosed investment just prior to the European Business Aviation Convention &amp; Exhibition (EBACE) in Geneva but did not specify a dollar amount. &nbsp;
On May 23, fractional ownership group Sky2Share announced it has placed pre-orders for 15 of the five-seat Cassio 330 model. The agreement takes the number of provisional sales commitments booked by VoltAero to 218, including both orders and options.
Swiss-based Sky2Share, which is committed to operating private flights with lower carbon emissions, has the option to change its order to take the larger Cassio 480 and 600 models. "We are impressed with VoltAero's progress in developing the Cassio aircraft family's clean-sheet design, which offers the right solution for our economically-viable and socially-responsible services as a truly sustainable alternative to traditional business aviation. We are thrilled that the Cassio family will allow us to radically reduce the environmental impact of our operations."
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 <div class="field field--name-field-caption field--type-string-long field--label-hidden field__item">Sky2Share plans to operate VoltAero's Cassio hybrid-electric aircraft as part of its fractional ownership fleet. (Image: Sky2Share)</div>
 
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<figcaption>Sky2Share plans to operate VoltAero's Cassio hybrid-electric aircraft as part of its fractional ownership fleet. (Image: Sky2Share)</figcaption>
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The Series B round marks the third funding phase for VoltAero, positioning it for the industrialization of its Cassio 330, the first member of Cassio’s electric-hybrid aircraft family. It builds on an earlier <a href="https://www.futureflight.aero/news-article/2022-11-02/voltaero-secures-eu32-million-and-production-partner-hybrid-electric-cassio">€32 million investment</a> by Italy's TESI group in November 2022.
“Kawasaki’s engine expertise and its capacity for innovation brings a new dimension to VoltAero as we complete the final definition of our electric-hybrid powertrain for the Cassio aircraft family,” said Jean Botti, VoltAero’s CEO and chief technology officer. “Having Kawasaki as a strategic investor is another major vote of confidence for the Cassio program.” However, the French start-up has not specified exactly how its new Japanese backer may contribute to the Cassio's propulsion system.
Featuring a forward fixed canard and aft-set wings with twin booms supporting a T-tail horizontal stabilizer, the Cassio will use <a href="https://www.futureflight.aero/news-article/2022-07-22/voltaero-partners-safran-and-thales-its-cassio-hybrid-electric-aircraft">Safran's EngineUs</a> electric motors in the aft fuselage-mounted propulsion system for all-electric power during taxi, takeoff, and landing. The hybrid feature – with an internal combustion engine – comes into play as a range extender, recharging the batteries while in flight. The hybrid element also serves as a backup in the event of a problem with the electric propulsion.
Cassio plans to offer three versions of the aircraft, each sharing a high degree of modularity and commonality. The company’s use case targets regional commercial operators, air taxi/charter companies, private owners, and utility-category services for cargo, postal delivery, and medevac applications.
<h3 class="subheading">Cassio Family Will Have Range Up to 800 Miles</h3>
Plans call for the five-seat Cassio 330, powered by the 330-kilowatt electric-hybrid propulsion system, to come first. VoltAero’s follow-on six-seat Cassio 480 would generate electric-hybrid propulsion power of 480 kilowatts, while the 12-seat Cassio 600 would feature useful power of 600 kilowatts.
The aircraft will be certified under EASA's CS23 certification specifications for single-engine, general aviation aircraft. Each Cassio aircraft will have a maximum range of about 800 miles (1,300 kilometers) and a cruise speed of around 230 mph (370 km/h).&nbsp; The all-electric range would be less than 94 miles (150 kilometers).&nbsp;
Headquartered at the Aérodrome de Royan-Médis in southwest France, Cassio plans to start final assembly in a purpose-built facility at the Rochefort Charente-Maritime Airport in France’s Nouvelle-Aquitaine region.
At the 2022 EBACE show, VoltAero announced plans to sell<a href="https://www.futureflight.aero/news-article/2022-05-19/voltaero-offers-fractional-shares-hybrid-electric-cassio-aircraft"> fractional shares</a> in the Cassio aircraft.
This story was updated on May 23 to add details about Sky2Share's pre-order for the Cassio 330 model.

Senior Editor

Gregory Polek

Kawasaki Motors Invests In VoltAero’s Cassio Hybrid-Electric Aircraft

VoltAero this week completed a €32 million ($32 million) Series B funding round to support its plans to develop its <a href="https://www.futureflight.aero/aircraft-program/cassio">Cassio family</a> of hybrid-electric aircraft. The round was led by strategic investor Tecnologie e Servizi Innovativi (TESI), which will manufacture the prototype for the five-seat Cassio 330 model, which is expected to make its first flight in 2023.
Italy-based TESI specializes&nbsp;in the production and integration of metallic structures and assemblies, as well as mechanical parts. The company says it has&nbsp;experience in aviation manufacturing with clients including Leonardo, PiaggioAero, and Boeing.
In July, VoltAero selected <a href="https://www.futureflight.aero/news-article/2022-07-22/voltaero-partners-safran-and-thales-its-cassio-hybrid-electric-aircraft">Safran’s EngineUs 100</a> electric motor and announced that it is partnering with Thales to implement&nbsp;airborne data collection and computing solutions for the <a href="https://www.futureflight.aero/aircraft-program/cassio">Cassio</a> aircraft.&nbsp;The French start-up’s propulsion system will use the motors for all-electric power during taxi, takeoff, primary flight, and landing. 
The hybrid feature—using an internal combustion engine—serves as a range extender, recharging the batteries while in flight. It also provides&nbsp;a backup in case&nbsp;of a problem with the electric propulsion.
VoltAero plans to produce three configurations of its hybrid-electric Cassio aircraft and earlier this year proposed a <a href="https://www.futureflight.aero/news-article/2022-05-19/voltaero-offers-fractional-shares-hybrid-electric-cassio-aircraft">fractional ownership business model</a> for them. Its initial prototype, a converted Cessna 337 Skymaster aircraft known as Cassio 1, has already logged more than 10,000 kilometers (6,000 miles) in test flights since 2019. The Cassio 1 testbed has two EngineUs 45 electric motors&nbsp;that are rated at 45 kilowatts of continuous power.&nbsp;
In addition to the Cassio 330, VoltAero plans to develop a six-seat Cassio 480 (480 kilowatts)&nbsp;and a&nbsp;10-seat Cassio 600 (600 kilowatts). The Cassio aircraft, which&nbsp;feature a forward fixed canard and an aft-set wing with twin booms that support a high-set horizontal tail, are designed for various general aviation and business applications, including air taxi services. 
The aircraft will be certified under EASA's CS23 certification specifications for single-engine, general aviation aircraft. Each Cassio aircraft will have a range of about 800 miles (1,300 kilometers) and a cruise speed of around 230 mph (370 km/h).&nbsp;
“We have been impressed by VoltAero’s highly intelligent approach with Cassio, applying its dual-source electric-hybrid propulsion concept for regional aviation that will be both sustainable and operationally safe,”&nbsp;stated TESI’s chief executive, Luigi Punzo.
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VoltAero Secures €32 Million and Production Partner for Hybrid-electric Cassio Aircraft

VoltAero has selected Safran’s EngineUs 100 electric motor to power its Cassio 330 prototype, and the company is partnering with Thales to implement&nbsp;airborne data collection and computing solutions for its <a href="https://www.futureflight.aero/aircraft-program/cassio">Cassio</a> family of hybrid-electric aircraft, the company announced this week at the UK’s Farnborough International Airshow.&nbsp;
The French start-up plans to produce three configurations of its hybrid-electric Cassio aircraft. Its initial prototype, a converted Cessna 337 Skymaster known as Cassio 1, has already logged more than 10,000 kilometers (6,000 miles) in test flights since 2019. The Cassio 1 testbed has two EngineUs 45 electric motors, which are rated at 45 kilowatts of continuous power.&nbsp;
Now VoltAero has announced that the four-seat Cassio 330, the company’s first production model, will use an EngineUs 100 motor, which has a maximum rating of more than 150 kilowatts. VoltAero and Safran signed the agreement on July 20 at the Farnborough International Airshow.
Safran has agreed to deliver the first EngineUs 100 motor by the end of the year when VoltAero will begin ground-based tests of its hybrid-electric propulsion system. Safran then plans to supply a flight-qualified EngineUs 100 motor in 2023, after which VoltAero will be able to begin flight testing of its first Cassio 330 prototype.&nbsp;
“This marks another important step toward the Cassio 330’s first takeoff, initiating the certification program for our Cassio family of airplanes,” said Jean Botti, VoltAero’s CEO and chief technology officer. “Cassio will benefit from the high-power density and proven technology that Safran Electrical &amp; Power has applied in its EngineUs electric motor product line.”
In addition to the Cassio 330, VoltAero plans to develop a six-seat Cassio 480 (480 kilowatts)&nbsp;and the&nbsp;10-seat Cassio 600 (600 kilowatts). The Cassio aircraft are designed for a variety of general aviation and business applications, including air taxi services. They will be certified under EASA's CS23 certification specifications for single-engine, general aviation aircraft. Each of the Cassio aircraft will have a range of about 800 miles (1,300 kilometers) and a cruise speed of about 230 mph (370 km/h).&nbsp;
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 <div class="field field--name-field-caption field--type-string-long field--label-hidden field__item">Thales installed a demonstrator of its FlytLink Edge Computing system on VoltAero's Cassio 1 testbed. (Credit: VoltAero/Jean-Marie Urlacher)</div>
 
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<figcaption>Thales installed a demonstrator of its FlytLink Edge Computing system on VoltAero's Cassio 1 testbed. (Credit: VoltAero/Jean-Marie Urlacher)</figcaption>
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Earlier this week at the Farnborough International Airshow, on July 19, VoltAero announced that it will work with the French aerospace technology group Thales to implement the company’s FlytLink Edge Computing system in its Cassio family of aircraft.&nbsp;
VoltAero says Thales’s data collection and computing system will enhance Cassio’s autonomy, sustainability, and operability. It uses a compact processor that’s connected to the cloud to enable real-time data collection, processing, and transmission from an aircraft’s onboard cameras and sensors. The companies have already begun validating the technologies on the Cassio 1 prototype.
“Potential future uses of Thales’s FlytLink Edge Computing solutions on production versions of the Cassio electric-hybrid aircraft family include optimizing route planning for flight operations that are even more efficient and environmentally friendly,” said VoltAero CEO and chief technology officer Jean Botti. “The real-time processing of imagery from onboard cameras with artificial intelligence could also support such functions as the detection of obstacles and air traffic, an asset for flight safety.”
“Developing innovative solutions for regional and urban air mobility needs to build on the best of avionics know-how, further improving the safety of these new aircraft and offering breakthrough solutions based on the most advanced technologies," added Marc Duval-Destin, vice president of strategy, product, and innovation of Thales flight avionics activities. “This is precisely what we are implementing with VoltAero—beginning on Cassio 1—to test and develop solutions that will make a difference for air transportation of tomorrow.”

VoltAero Partners with Safran and Thales for Its Cassio Hybrid-Electric Aircraft

VoltAero has had to postpone plans for a week of demonstration flights with its Cassio hybrid-electric aircraft in the Netherlands. That's because&nbsp;Dutch aviation regulators refused to accept the experimental approval that had already been agreed upon by their counterparts in France, where the start-up is based. In a July 11 statement confirming the postponement of plans announced in May, the company called on European airworthiness authorities to more closely coordinate and standardize their approach to regulating new electric aircraft.
The Cassio 1 technology demonstrator aircraft had been expected to be part of Dutch efforts to introduce electric-powered commercial passenger flights within five years under its <a href="https://www.futureflight.aero/news-article/2022-05-24/voltaeros-cassio-hybrid-electric-aircraft-perform-demo-flights-netherlands">Power Up</a> initiative.&nbsp;In the flight trials, program engineers had planned to assess operational costs, noise performance, ground infrastructure requirements, and technical support for the future use of Cassio family aircraft by commercial aviation operators. 
The Power Up initiative involves the four main regional airports in the Netherlands (Eindhoven Airport, Rotterdam The Hague Airport, Groningen Airport Eelde, and Maastricht Aachen Airport) with the support of the Schiphol Group and other partners aimed at facilitating and stimulating the introduction of electric Regional Air Mobility (eRAM) in the Netherlands. A so-called open-source accelerator, the initiative brings together aircraft manufacturers (OEMs), airlines, and airports in a joint effort to improve regional connectivity.
The suspension of Cassio’s involvement in the flight trials happened during final preparations when VoltAero says a “mismatch” between the French and Dutch regulations became apparent. Dutch regulations stipulate that only aircraft registered in the Netherlands can conduct flight testing in its airspace and using its airports. According to the company, in France experimental aircraft like the Cassio 1 are not generally registered as “normal” aircraft.
In an effort to resolve the administrative disconnect, France’s DGAC agency issued a statement to clarify Cassio’s legal standing but this was not sufficient for the Dutch regulator. VoltAero complained that this unforeseen problem has revealed inconsistencies in how development work on new aircraft is regulated by different European states, even those that are members of EASA.
According to VoltAero CEO Jean Botti, the difficulties could undermine efforts to certify new sustainable aviation technology. “It is heartbreaking to see that the joint efforts of VoltAero and Power Up have been blocked by these inconsistencies,” said the former Airbus executive. “This is not only a problem for our specific demonstration flights, which would have involved just five days of flying; it could hinder the electric aviation industry’s evolution as a whole. There is a need for testing new technologies across countries and borders. We call on policymakers throughout Europe to work towards harmonized regulations to ensure that the development of new sustainable aircraft technology can be achieved as efficiently as possible.”
VoltAero’s proprietary electric-hybrid powertrain has undergone extensive airborne evaluations since 2020 on the Cassio 1 testbed in its 600-kilowatt full-power output. Cassio 1 has flown more than 10,000 kilometers (5,400 nm) in operations in France and the UK as VoltAero readies the propulsion system and battery chain for airworthiness certification.
Cassio aircraft will use their propulsion system’s electric motors for all-electric power during taxi, takeoff, primary flight, and landing. The hybrid feature—using an internal combustion engine—serves as a range extender, recharging the batteries while in flight. The hybrid element also serves as a backup in the event of a problem with the electric propulsion.
VoltAero plans three production versions of the Cassio aircraft, ranging in capacity from four to 12 seats. It is marketing&nbsp;the family for operation with airlines, <a href="https://www.futureflight.aero/news-article/2021-07-23/kinectair-offers-fractional-shares-voltaeros-hybrid-electric-cassio">air taxi/charter companies</a>, and <a href="https://www.futureflight.aero/news-article/2022-05-19/voltaero-offers-fractional-shares-hybrid-electric-cassio-aircraft">private owners</a>, as well as for utility-category service for cargo, postal delivery, and medical evacuation (Medevac) applications.
The company plans first to gain certification for the Cassio 330, which carries&nbsp;four or five seats and is powered by a 330-kilowatt electric-hybrid power module. The company’s six-seat Cassio 480 will feature 480 kilowatts of electric-hybrid propulsion power, while the 10- to 12-seat Cassio 600 will fly on 600 kilowatts.
The Cassio design features a forward canard and an aft-set wing with twin booms that support a high horizontal tail. The company plans to gain certification to Europe’s EASA CS23 specification in the single-engine, general aviation category.
VoltAero intends to build the <a href="https://www.futureflight.aero/aircraft-program/cassio">Cassio</a> aircraft at a dedicated facility at Rochefort Airport in France’s Nouvelle-Aquitaine region. It expects to break ground on the plant this year.
The concerns raised by VoltAero this week about apparent inconsistencies in rules governing test flights of experimental aircraft surfaced within days of the UK’s Air Accident Investigation Branch publishing a report into an April 2021 crash involving a Piper M Series used by ZeroAvia to evaluate its hydrogen propulsion system. The report recommended several changes to the oversight of flight tests.
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Dutch Regulators Stop VoltAero's Plans for Hybrid-Electric Cassio Test Flights

Electric Power Systems is set to supply the first of its Epic energy storage systems for the prototype of VoltAero’s Cassio 330 hybrid-electric STOL aircraft. Under an agreement announced by the companies on January 27, the first unit will be delivered by the end of June to be integrated into the French start-up’s four-seat model, which will operate with a combined hybrid-electric power output of 330 kW.
The production versions of the Cassio will be powered by&nbsp;three of Safran’s 60-kW Engineus 45 electric motors and a 370-hp internal combustion engine,&nbsp;collectively driving a five-bladed pusher propeller. The first Cassio 330 model is due to be delivered in the fourth quarter of 2023, and VoltAero is planning for production rates of up to 150 aircraft per year.
According to the Utah-based powertrain specialist, its Epic system incorporates power cell technology that offers an energy density of more than 200 Wh/kg in its battery packs. The equipment, which can be scaled in capacity with modular units to support various&nbsp;sizes of aircraft, can run more than 2,000 fast-charge cycles before having to be replaced.
The Cassio 330 is the smaller of three fixed-wing aircraft that VoltAero is developing. The six-seat Cassio 480 will have 480 kW of power, while the 10-seat Cassio 600 will have 600 kW.
The company, which was founded by former Airbus chief technical officer Jean Botti, has already flown its Cassio 1 technology demonstrator almost 5,300 miles on what it says are typical air taxi routes within Europe. These flights used the same hybrid-electric powertrain that will now be fitted for the Cassio production aircraft, which are to be manufactured in a purpose-built factory at Rochefort Airport in France’s Nouvelle-Aquitaine region.
Airframe and aerostructures manufacturer Sonaca Aircraft is conducting engineering design for the Cassio airframes and will supply these for series production aircraft.
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VoltAero Selects Energy Storage System for Hybrid-Electric Cassio Aircraft

Private aviation platform KinectAir is offering fractional shares in VoltAero’s Cassio hybrid-electric aircraft. In a joint announcement on July 22, the companies said that customers can now reserve share positions in the four-seat Cassio 330 model, for which deliveries are due to begin in the fourth quarter of 2023.
U.S.-based KinectAir said it will launch its Pioneer fractional ownership program at next week’s EAA AirVenture show in Oshkosh, Wisconsin. It has not yet provided full details about terms and conditions&nbsp;or pricing but did say that customers can also place reservations&nbsp;for complete aircraft. The company did indicate that the Pioneer program would allow owners to earn revenue to offset costs by permitting other people to fly in the aircraft in an arrangement it compared to Airbnb.
According to KinectAir, the Cassio 330s will be positioned at various U.S. airports based on user demand. It did not say who will operate the aircraft, but it has previously announced plans to secure an air operator&nbsp;certificate.
The Cassio aircraft are expected to have a range of up to 800 miles and fly at speeds of up to 230 mph. VoltAero intends to certify the aircraft under Part 23 rules and says they will require only 1,800 feet of runway to take off and land.
“The Jetsons future of rooftop-to-rooftop travel we see in very promising [eVTOL aircraft] projects like Joby and Beta is just a long way off,” said KinectAir CEO Jonathan Evans. “The Cassio brings an efficient and elegant clean-sheet design for an aircraft that can take off and land on the smaller, local airfields we are already operating from, and we expect to bring it into the fleet as early as 2024.” In fact, leading eVTOL aircraft developers including Joby and Beta also say they will have products certified and in commercial service by 2024.
In July 2020, KinectAir announced plans to launch a portfolio of on-demand flights, per-seat charter, and fractional aircraft ownership, saying that it would include hybrid-electric fixed-wing and eVTOL aircraft in its fleet. Plans called for the launch of its Together charter program by the end of the second quarter of 2021 with a fleet of leased aircraft.
Previously, KinectAir indicated that each aircraft will operate around 750 hours per year and with five owners per airframe. It aims to have a minimum of eight aircraft available in each region where it operates, with plans to start in Washington state, the San Francisco Bay area, and&nbsp;the UK. 
VoltAero says that it intends to produce 150 aircraft per year in its new factory at Rochefort Airport in southwest France. It also holds provisional orders for 15 Cassio aircraft from Airways Aviation, which is a pilot-training company with ambitions to start passenger service in the south of France.
In addition to the Cassio 330, VoltAero is developing larger six- and 10-seat versions of the fixed-wing aircraft called the Cassio 480 and 600 models. The numbers in each model name refer to their power rating in kilowatts. 
The production versions of the Cassio will be powered by&nbsp;three of Safran’s 60-kW Engineus 45 electric motors and a 370-hp internal combustion engine and a 370-hp internal combustion engine, collectively driving a five-bladed pusher propeller. The Cassio 1 demonstrator aircraft has a pair of forward-mounted propellers, each driven by an Engineus 45 motor. 
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KinectAir Offers Fractional Shares in VoltAero's Hybrid-Electric Cassio Aircraft

VoltAero will build its Cassio family of hybrid-electric aircraft at a new purpose-built factory at Rochefort Airport in the southwest of France. The company announced the selection of the site after landing the Cassio 1 technology demonstrator aircraft at the airport on July 11 at the end of an 11-stage promotional tour of the country.
Work on the 6,770-sq-m&nbsp;(72,874-sq-ft) facility, which will incorporate a final assembly line, logistics areas, and offices, is set to begin in the second quarter of 2022. The first four-seat Cassio 330 model is due to be delivered in the fourth quarter of 2023, and VoltAero is planning for production rates of up to 150 aircraft per year.
In addition to the Cassio 330, VoltAero is also developing larger six- and 10-seat versions of the fixed-wing aircraft called the Cassio 480 and 600 models. The numbers in each model name refer to their power rating in kilowatts.
“After an in-depth review of numerous candidate sites, Rochefort was the clear winner based on factors that include its ground- and sea-based transportation links, an established aerospace industry in the region, and the final assembly line’s favorable location adjacent to the airport’s runway infrastructure,” explained VoltAero CEO and chief technology officer Jean Botti.
Rochefort is in the Charente-Maritime department of France’s Nouvelle-Aquitaine region. VoltAero has been based in the area since it was launched in September 2017 by Botti, who was formerly chief technology officer for Airbus’s E-Fan electric aircraft program. The company has received financial support from the Nouvelle-Aquitaine regional government.
The production versions of the Cassio will be powered by&nbsp;three of Safran’s 60-kW Engineus 45 electric motors and a 370-hp internal combustion engine,&nbsp;collectively driving a five-bladed pusher propeller. The Cassio 1 demonstrator has a pair of forward-mounted propellers, each driven by an Engineus 45 motor. 
Airframe and aerostructures manufacturer Sonaca Aircraft is conducting engineering design for the Cassio airframes and will supply these for series production. Aero Composites Saintonge is working on battery assembly and has produced components for the demonstrator aircraft. VoltAero is seeking to recruit aerospace engineers from French schools such as the &nbsp;Université&nbsp;de Bordeaux.
The projected range for the aircraft, which are intended for various applications including scheduled and on-demand passenger transportation, is up to around 750 miles and they will fly at&nbsp;a speed of around 230 mph. They will be able to take off and land in less than 1,800 feet and will be certified under EASA's CS-23 rules.
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VoltAero

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