Supernal, Qarbon Aerospace partner to mature induction welding technologies for eVTOL scale-up 

Supernal LLC (Washington, D.C., U.S.) and Qarbon Aerospace Inc. (Red Oak, Texas, U.S.) are partnering to mature component welding techniques for future scaled production of electric vertical takeoff and landing (eVTOL) vehicles. This marks the first of two agreements Supernal has recently announced — the other with GKN Aerospace — with established aerospace manufacturers, as the company works to develop a novel manufacturing process that will enable the advanced air mobility (AAM) industry to meet expected demand in the coming decades.

As a manufacturer of composite components and assemblies for commercial and military aircraft and spacecraft (read CW’s “Plant tour: Qarbon Aerospace, Milledgeville, Ga. and Red Oak, Texas”), Qarbon Aerospace will work with Supernal to apply its induction welding technology to the assembly of the company’s S-A1 carbon fiber-reinforced thermoplastic (CFRTP) vehicle components. The companies will work to scale Qarbon Aerospace’s established welding process, developing a manufacturing roadmap to meet future eVTOL vehicle order demands.

According to Aviation Week, Supernal’s company’s S-A1 eVTOL is designed to carry a pilot and four passengers up to 97 kilometers at speeds of up to 180 miles per hour.

“Supernal is thrilled to partner with Qarbon Aerospace to advance rate-enabling manufacturing processes for the AAM industry,” says Jaiwon Shin, president of Hyundai Motor Group and CEO of Supernal. “By incorporating advanced materials and processes in our manufacturing strategy from the start, Supernal will be prepared to expand eVTOL vehicle production capacity to meet demand surges when the industry takes off.”

Supernal is investing significant time and resources into creating a new form of aviation manufacturing that marries aerospace’s high certification standards and automotive’s high-rate production technologies. In the current phase, the company is partnering with major aerospace suppliers, such as Qarbon Aerospace, to improve processes and costs associated with the joining of lighter weight components for its eVTOL vehicles. 

“We are excited that Supernal has selected Qarbon Aerospace’s thermoplastic welding technology to enable the high-rate manufacturing of their eVTOL vehicle structure,” adds Pete Wick, CEO, Qarbon Aerospace. “Supernal’s deliberate approach of carefully selecting and integrating rate-enabling technology from the start differentiates their eVTOL vehicle in the AAM field, and we are proud that our technology is going to support Supernal’s inevitable success in the AAM industry.”

Qarbon Aerospace has previously partnered with startup LIFT Aircraft, which is developing a one-seater personal multicopter.