FLYING Magazine
Bye Aerospace on Thursday announced the successful first flight of the eFlyer 2, its all-electric aircraft. The flight marks a major milestone for the Colorado-based company and the future of electric training aircraft.
According to company officials, the first flight signifies the launch of the aircraft’s flight test program and advances Bye Aerospace toward FAA certification and customer deliveries. They said the eFlyer 2 is designed to dramatically reduce operating costs and carbon emissions while enhancing the flight experience for general aviation.
The eFlyer 2 is designed specifically for the flight training market, combining an advanced electric propulsion system with a lightweight composite airframe. The company said the safety-focused design reduces operating costs by up to 80 percent while eliminating in-flight emissions.
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Bye Aerospace chief test pilot Elliot Seguin was at the controls of the eFlyer 2 as it completed its planned flight test profile from Centennial Airport (KAPA) near Denver.
The flight enabled the team to perform an initial evaluation of the aircraft’s handling qualities, aerodynamic characteristics, and system performance, while collecting data to support the next phase of flight testing.
“We included a test pilot early in the assembly and testing phases of the program,” said Rod Zastrow, CEO of Bye Aerospace, in a news release. “[Seguin] was actively involved in planning, troubleshooting, analyses, and decisions tied to engineering and assembly options. He was integrated into the aerodynamics and flight-handling characteristics and preflight analysis. And he was crucial in helping us upgrade our existing flight simulator to better emulate the anticipated flight-handling and performance characteristics.
“He flew the planned mission at the planned airfield dozens of times to explore various scenarios and practice certain emergency procedures. In short, the collective efforts well prepared him for the first flight, which he executed flawlessly. I could not be more pleased and proud of his performance.”
Seguin also shared his thoughts on achieving this key milestone.
“First flights are always significant moments for any new aircraft program,” said Seguin. “The eFlyer 2 handled well during the flight and validated the work the engineering team has put into designing and testing the aircraft over the past several years. It’s exciting to help advance a platform designed specifically for the future of pilot training.”
Zastrow noted the team took a conservative approach to the first flight profile given the unknowns associated.
“We planned and executed a single lap in the Centennial Airport pattern at 1,000 feet agl,” he said. “We gathered a lot of initial data from both the aerodynamics, flight handling, and system performance in the two most rigorous phases of flight—takeoff and climb (power and lift performance) and landing (handling characteristics). Our future extensive flight test program will increasingly work to expand the operating flight envelope and handling characteristics.”
Design Details
The eFlyer 2t is powered entirely by electricity.
It features a high-voltage system that operates up to 800 volts, with the batteries, controlled by the power distribution unit, supplying propulsion energy, and, through a DC-to-DC voltage converter, stepping down the 800 volts to 28 volts, which powers the entire low-voltage system (communications, navigation, lighting, etc.)
“Our ‘fuel tank’ is the battery pack consisting of magniX Samson battery modules, which are located in the forward and aft battery bays,” said Zastrow. “The layout and aero efficiency gained by the electric system included a much sleeker fuselage, starting at the nose. Because there are no fuel tanks there is reduced wing mass and improved aerodynamic characteristics.
“New airfoils from wing root to tip improved efficiency, slow flight, stall and anti-spin characteristics. Our team stepped up and got it right. And part of that success was that we have great partners for the engine, batteries, and power lever.”
Technology Behind the Achievement
Developing the all-electric trainer required designing and integrating entirely new systems from the ground up, according to Zastrow.
“The novel technology comprises the electric propulsion system that includes changes ranging from the propeller, to the Safran first-ever certified aviation engine, to the electric storage system (battery and power distribution, and charger port), to the power lever and pilot interface,” he said. “We needed new hardware and software for each sub-system and needed to create new software to integrate all those subsystems.”
The eFlyer 2 includes technologies from global aerospace and advanced manufacturing suppliers, including Safran Electrical & Power, MagniX, Siemens, Toray, Composite Approach, Garmin, Sensenich Propeller, Electro.Aero, Flying S, M4 Engineering, Acme Aero, and Risse Racing.
It Takes a Village
The Bye Aerospace team consisted of engineers and technicians who focused on design, assembly, and testing supported by teams dedicated to making sure all of them had the parts, tools, equipment, and software needed to make the eFlyer 2 a reality.
“Key supply contractors were essential participants throughout…, ” said Zastrow. “We had a great project manager augmented by an outstanding supply chain manager who, together, ensured we executed on budget and on time, as circumstances allowed.”
Bye Aerospace said it has over 1,000 total orders with approximately 40 percent being paid, nonrefundable orders, with the rest captured in letters of intent.
Flight schools will have to pay for added infrastructure in the form of fast-charging capability similar to what is used for electric vehicles but will no longer be relying on fossil fuels to power aircraft.
“Fifty percent of our orders are from international customers from all continents,” Zastrow said. “In short, the eFlyer is attractive to a global need for lower-cost pilot training. The current list price is $745,000. However, customers are compelled by the 80 percent reduction forecast for the operating costs, including maintenance, scheduled propulsion overhauls, and energy [fuel]. Thus, we are excited to continue with the planned flight test program based on this solid foundation of design, build, test, and flight execution.”
The eFlyer 2 has operating costs forecast at $35-$40 per hour versus legacy aircraft such as Piper, Cessna, Beechcraft, and Diamond that cost approximately $165-$175 per hour to operate.
Bye Aerospace intends for the production eFlyer 2 to have fixed landing gear and a fixed-pitch prop and a top design speed of 140 knots with a design VNE of 160 knots.
Other critical speeds, such as best glide, will be confirmed through future flight testing.