CAeS was contracted by Airbus to support the E-Fan X project, a complex hybrid-electric flight demonstrator, which replaces one of the engines with a 2 MW electric motor.
CAeS designed and verified the structure to install and operate the jet engine/electric generator inside the fuselage of the BAe 146 flying testbed.
https://www.airbus.com/en/innovation/low-carbon-aviation/hybrid-and-electric-flight/e-fan-x
BATTLE OF BRITAIN MEMORIAL FLIGHT
CAeS and its predecessors supported the UK’s Battle of Britain Memorial Flight for 40 years.
In that time, we have developed avionics modifications, structural repairs and provided Independent Technical Evaluation of third-party modifications. We have also provided continual design, airworthiness and safety advice to structures and systems for the Flight’s fleet of Spitfires and Hurricanes.
CAeS supported the design, development, integration and installation of a wide range of equipment for this unique aircraft modification.
CAeS also delivered the certification process, including flight testing.
Complex Flight Test Instrumentation (FTI) suite measuring all flight control movements, processes the data, and displays it directly to each student
New equipment rack housing data acquisition and management equipment (installed Data Acquisition Computer,
Inertial Measurement Unit, Sideslip Vanes, Navigation System, GPS Splitters)
Cockpit interface in centre pedestal that allows full control of the FTI equipment, battery isolation, master switch, WiFi
switch, etc.
Charging for the students’ tablets via USB or 240V AC.
Camera System for external forward view, cockpit view, and wing view
WiFi System supporting wireless data transmission inside the passenger cabin (including T-PED testing for compliance demonstration)
Installation of a passenger door in the rear bulkhead to make the cargo compartment accessible in flight
Installation of a FLARM Safety System, enhancing situation
awareness for the flight crew
Intercom headset sockets for classroom demonstrators
Certification Basis included Certification Review Items for
“Lithium Battery Installations” (CRI F-04) and “WLAN and Interfacing (T-)PEDs” (CRI F-01)
CAeS was contracted by Thales to support the integration of FASGW(L) system and by the MOD to support the integration of legacy Stingray torpedo and depth charge systems onto the Augusta Westland Wildcat helicopters. We also worked alongside MBDA who were supporting the FASGW(H) system and Leonardo helicopters who operated the helicopter.
Supporting the integration of defensive aids onto the Chinook Mk5 and Mk6 helicopters and F-35.
Data collection was conducted using bespoke CAeS hardware that was manufactured in collaboration with UK MOD to support flight trials. The hardware consists of an array of data loggers and sensors fitted to a standard Type 118 flare case. This reduces minimal installation effort into standard flare magazines with minimal interference with aircraft systems that enables faster safety assessments, clearance and turnaround during trials.
11 years of development with NASA, US Airforce and Boeing to design fully representative systems.
CAeS designed and built the X-48 B and C variants in the UK.
Blended wing concept design, considered a contender for future aircraft.
CAeS developed to test aerodynamic characteristics near stall speeds.
CAeS designed the aircraft systems and ground station for piloting the vehicle.
CAeS built the flight test demonstrator, support wind tunnel testing.
CAeS supported 7 years of flight testing
The X-48B, is the unmanned X-plane with the most sorties – 130.
Experimental ground vibration test of the air vehicle to allow:
Validation of finite element model – mass, stiffness and interfaces
Validation of flight control model – quantify any coincidences of resonances with flight control frequencies
Low frequency GVT to assure the aero-elastic and stability
42 m wingspan, but extremely light
Modes expected at very low frequencies
Special low frequency instrumentation acquired
Suspension springs designed and manufactured for the test
Support to the Certification of modifications to CAA/DAOS Approvals
CAeS provides structural and aerodynamic leads for the ‘major’ modifications involved.
Design Services including,
Mechanical and electrical system design
Stress analysis (static, fatigue and damage analysis)
Icing Predictions
Modification to Pressure Bulkhead
Weight and Balance Reports
Flight Performance Determination
Flight trials
Certification
OLM support
Wind tunnel testing
Provision of CVEs and signatories
Support Agreement with U-TacS
Elbit (Silver Arrow)/Thales JV
Support/advice to Elbit on UK MoD certification.
Review of all certification documentation
Major step forward in certifying UAV’s for flight in UK airspace.
Load case analysis on entire vehicle
Modifications to aircraft.
CAeS was contracted by BAE Systems to design and certify various complex modifications on the FAAM BAE 146 Airborne Laboratory under our BCAR A8-21 approval. The aircraft is extensively used for atmospheric research across the world. CAeS modifications include various external apertures for sensors, cameras, and antennas as well as internal modifications for operator consoles, avionics, and supporting structures.
In 2025, Safran central technologies (Paris) commissioned CAeS to support the development of their own hydrogen
programmes.
Working with the Safran team, CAeS are developing a 50-PAX regional aircraft to design, test and iterate with
new hydrogen powertrain pseudo technologies. With CAeS acting as both pseudo airframer and technology supplier, models with flight analysis provide the teams the opportunity to understand the environmental and
performance challenges associated with the state-of-the-art technology being developed.
By exploring the integration of complex next generation system technologies through the product life-cycle, CAeS and Safran are able to accelerate early-stage developments, expose aircraft level technology challenges and increase system efficiency.
CAeS was contracted by Airbus to support the E-Fan X project, a complex hybrid-electric flight demonstrator, which replaces one of the engines with a 2 MW electric motor.
CAeS designed and verified the structure to install and operate the jet engine/electric generator inside the fuselage of the BAe 146 flying testbed.
https://www.airbus.com/en/innovation/low-carbon-aviation/hybrid-and-electric-flight/e-fan-x
CAeS was contracted by Rolls-Royce to verify the flight safety data under UK CAA E Conditions (CAP1220) for the all-electric “Spirit of Innovation” aircraft, which is the world’s fastest all-electric aircraft. It reached a top speed of 345.5 mph over a 3 kilometres stretch.
CAeS verified all the related documents including risk and safety assessments.
Californian-based private aviation and fractional ownership innovator Stratus 9 signed a deal with CAeS in February 2024 to create the United States’ first zero-emission fractional aircraft and co-ownership programme.
MONTE is a global asset manager, founded with the sole ambition of financing sustainable regional transportation. Our partnership with MONTE allows us to offer extend financing options to operators when purchasing our modification kits or conversions.
A startup airline planning to operate exclusively sustainable aircraft, Evia Aero aims to reactivate regional markets and expand air travel in a scalable, sustainable and economically viable way. CAeS is one of the airline’s two technology partners.
Dronamics have developed the Black Swan, a middle-mile cargo UAV and have been granted both an IATA & ICAO operator designation and an AOC (Air Operator Certificate) in Europe. Although they will launch their operations with conventionally-powered UAVs, the MOU signed with CAeS in 2023 and the subsequent Letter of Intent for nearly 1300 CAeS hydrogen powertrains underlines their intent to transition to a sustainable solution for their platform.
A 100% indigenously-owned air charter company based in the beautiful island community off the northern coast of Australia, Torres Strait Air has been operating Islanders for almost 10 years. A LOI signed with MONTE in September 2023 recognises the operator’s intention to convert its Islander fleet to hydrogen-electric propulsion.
British reginal airline Skybus is owned by the Isles of Scilly Steamship Group (ISSG) and has been operating Islanders between the UK mainland and the Scilly Isles for over 30 years. ISSG signed a Letter of Intent with CAeS and Britten Norman in 2021 in recognition of their ambition to transition their air services to hydrogen.
Air New Zealand are a major international airline renowned for their focus on sustainability.
Cranfield Aerospace were selected as Air New Zealand’s hydrogen technology partner on their Mission Next Gen Aircraft Programme which was created to accelerate the development of next generation aircraft technologies and the infrastructure required to make them a reality for commercial aviation in New Zealand.
https://www.airnewzealand.co.uk/
https://flightnz0.airnewzealand.co.nz/initiatives/mission-next-gen-aircraft