A big idea takes flight

Source: HM Government, www.greatbusiness.gov.uk

It’s bigger than a football field, making it the world’s largest aircraft (about 60 feet longer than an Airbus A380). It is a mixture of aeroplane, airship, helicopter and hovercraft. It’s greener and quieter than other air transport. Oh, and a larger version is already in prototype. And it’s all being designed and built in Bedfordshire.

The helium-filled Airlander is the creation of Hybrid Air Vehicles (HAV), a seven-year-old company that itself was born out of decades of British innovation and research in Lighter Than Air (LTA) craft.

HAV was able to make the step from initial prototype to the manufacture and test flight thanks to a 2010 contract from the US Department of Defence. Led by Northrop Grumman, the aim was to create a so-called Long Endurance Multi-Intelligence Vehicle (LEMV) – a super-sized surveillance aircraft that had the capability of spending days in the air on a single mission.

The first test flight of the Airlander took place in August 2012. But in 2013, budget cuts led to the cancellation of the project. HAV bought it back from the DoD at effectively scrap value.

“We remain on very good terms with the US Department of Defence,” says HAV’s communications director Chris Daniels. “We continue to share data with them and we expect our dialogue to bear fruit in the future.”

So the Airlander came back to the UK, where it lives in a giant hangar in Cardington, Bedfordshire. It’s there because it’s is the only place in the UK that can house it, having been built for airship manufacture in 1915.

One hundred years ago, Bedfordshire was at the cutting edge of aviation. Now it is again. 

At present, Airlander 10 can carry up to ten tonnes and can stay airborne for up to five days. It is envisaged that Airlander 10 might be used for surveillance and communications, for filming, research and survey work.

However, there is (literally) a bigger picture. HAV’s aim is to transform and disrupt the cargo market by building a craft that will be able to carry 50 tonnes – the Airlander 50.

This enormous construction will be able to transport goods and equipment literally to all corners of the earth. It can land on water, desert or ice, enabling access to remote and inaccessible places, from the jungles of Africa to the icy terrain of Canada.

“All the studies indicate that there is a market for up to 1,000 of these craft,” says Daniels.

That’s because Airlander 50 transforms a key metric for transportation: the cost per tonne kilometre (ie. the amount it costs to carry one tonne over one kilometre). For example, a mining company could slash the costs of transporting ore from a remote mine to a processing plant.

By delivering point to point, it will also reduce the frictional costs of transportation. The more borders and ports through which a cargo has to pass, the more it incurs bureaucracy and paperwork and, in many cases, the greater possibility of spoilage and theft of goods. Airlander will be able to travel from source to site. And its environmental credentials mean that it can claim to be the greenest form of cargo transport.

Funding for prototyping

It is for the prototyping and broad technological development of Airlander 50 that HAV secured £2.5m from Innovate UK alongside investment from a group of private investors. (One of the investors is Bruce Dickinson, lead singer of Iron Maiden, whose presence on the shareholder register gives literal rock star status to the venture.)

This really is a British SME with the potential to lead the world in its field.

The development is being led by HAV with other world-class British firms including avionics experts Bluebear Systems and materials company Forward Composites and specialist teams from Cranfield, Liverpool and Sheffield universities.

Funding to unlock private investment

Hybrid Air Vehicles has also been the recipient of a significant grant from the Regional Growth Fund, in one of 56 new awards announced on 12 February 2015.

The backing immediately unlocks equity investment from private individuals and will ultimately lead to commercial agreements with customers, who will continue the funding of the business through a series of trials and demonstrations taking place during 2016.

“We are delighted to have received RGF funding,” says Stephen McGlennan, CEO of HAV. “The commitment of the UK Government to our business is vital, and this will ensure we fly our innovative Airlander aircraft and enter the commercial market. To achieve this we need to create jobs, and the RGF grant immediately helps us to do this.”
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HAV AWARDED PRODUCTION ORGANISATION APPROVAL
Hybrid Air Vehicles has been awarded Production Organisation Approval from the Civil Aviation Authority. As 2018 came to a close, the Civil Aviation Authority (CAA) awarded Hybrid Air Vehicles Ltd a Production Organisation Approval. Following the successful award of our Design Organisation Approval from the European Aviation Safety Agency (EASA) in October 2018, this latest achievement sees HAV starting 2019 in a strong position to launch production. A Production Organisation Approval (POA) considers the manufacture and assembly aspects of aircraft production. This includes supply chain management, processes relating to manufacture and assembly, and the production facility itself. Both the Design Organisation Approval (DOA), which covers design activities and flight test, and the POA, covering manufacture and assembly, are required to move forward into a type certification programme with the production Airlander 10. Being awarded the POA in 2018 is a remarkable achievement. It typically takes over a year to prepare a facility for a POA audit. HAV only moved into our production facility, the Airlander Technology Centre, in June and were able to be audit-ready in under six months. This success is down to the effort of the Production team, led by Ivor Pope. In addition to preparing the facility, the team at Technology House has been working to establish rigorous supply chain and quality assurance processes. "The POA approval is a significant milestone for HAV. It is the culmination of months of hard work and focused effort," comments David Lindley, HAV’s Head of Aviation Safety & Quality Assurance. "It demonstrates that the safety, quality assurance, and supply chain management processes are in place, along with the production facility." "Successfully being awarded our POA in the same year as our DOA is fantastic," adds Executive Director Nick Allman. "The POA is the regulator’s stamp of approval for us to move ahead with the productionisation of Airlander 10 on the path to type certification. This puts us in a great position going into 2019."  

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