Vertical Aerospace launches battery pilot production line for Valo

Vertical Aerospace battery pilot production line is now operational at its Vertical Energy Centre. The 15,000 sq ft Vertical Energy Centre opened in 2023 and has produced the battery systems used in the Company’s piloted flight testing since 2024. These proprietary batteries have demonstrated industry-leading performance, delivering up to 1.4 MW of peak power during flight testing. The facility has now been upgraded with automated, aerospace-grade manufacturing processes designed to support certification and production, improving efficiency, consistency, and battery performance.

Vertical will use the pilot line to test and build the final battery packs for its seven Valo certification aircraft which will be used to take the aircraft through the final stages of its certification programme with the UK Civil Aviation Authority and the European Union Aviation Safety Agency, while also providing capacity for the first phase of commercial production following certification, targeted for 2028.

Stuart Simpson, CEO of Vertical Aerospace, commented: “Bringing our automated battery production line online is a defining step in our journey toward certification and commercialisation. We are not only developing a world-class aircraft - we are building the industrial capability required to produce it. Vertical’s phased approach aligns manufacturing capability with its certification roadmap and early commercialisation strategy. By investing early in aerospace-grade battery manufacturing, we are reducing integration risk, strengthening supply chain control and preparing for commercial service.”

Industrial capacity supporting commercialization

Vertical’s proprietary battery system powers both the electric Valo eVTOL aircraft and the hybrid-electric aircraft programme. While Vertical partners with tier-one aerospace suppliers including Honeywell, Aciturri and Syensqo across much of the aircraft’s development and assembly, the battery system remains a core in-house technology and a key value driver for the business.

Beyond aircraft sales, batteries are expected to generate recurring revenue throughout the aircraft lifecycle. Vertical expects to supply approximately 20 battery packs per aircraft over its operational life, creating long-term predictable revenue streams.

By 2035, Vertical expects to have supplied up to approximately 45,000 battery packs across its aircraft fleet.

Expanding manufacturing capability

Alongside the pilot production line, Vertical continues to expand its manufacturing capability through the development of Vertical Energy Centre 2 (VEC2), its powertrain hub.

VEC2, a new 30,000 sq ft facility adjacent to the existing site, is expected to open later this year and will triple battery production capacity. By 2027, Vertical expects to have invested £6.4 million / $8.5 million across the VEC and VEC2 facilities.

Growing UK aerospace capability

Vertical continues to expand its footprint in the South West of England, where the Company currently employs approximately 450 people. The Company expects to announce the location of its full-rate production and battery facilities, with locations in the UK and beyond under consideration and a final decision expected later this year, ready to meet Vertical’s manufacturing ramp up.

As production scales, Vertical expects the number of highly skilled jobs associated with its manufacturing ecosystem to rise to at least 2,220 by 2035.