Vertical Aerospace Ltd. has activated its battery pilot production line at the 15,000‑sq‑ft Vertical Energy Centre, a key step toward the 2028 launch of its Valo electric vertical‑takeoff and landing aircraft.
The new line will manufacture battery packs for the company’s seven certification aircraft, with each aircraft expected to use about 20 packs over its operational life. The company plans to supply up to 45,000 packs across its fleet by 2035, a figure that underpins its “battery‑as‑a‑service” model and the recurring revenue it hopes to generate as production scales.
“Bringing our automated battery production line online is a defining step in our journey toward certification and commercialisation,” CEO Stuart Simpson said. “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.”
The facility, which opened in 2023, is expected to triple production capacity when the second site, VEC2, opens later in 2026. Total investment in both sites is projected to reach £6.4 million (about $8.5 million) by 2027. Flight testing of the Valo’s batteries has been ongoing since 2024, with the packs delivering up to 1.4 MW of peak power during flight tests.
Certification of the Valo will be overseen by the UK Civil Aviation Authority and the European Union Aviation Safety Agency. The company’s pre‑order book stands at roughly 1,500 aircraft, valued at about $6 billion, and includes potential orders from American Airlines (up to 250 aircraft and $25 million) and Bristow Group. Partners such as Honeywell, Aciturri and Syensqo support the program’s development and supply chain.
Despite the operational milestone, Vertical Aerospace faces significant cash burn and negative levered free cash flow. The company’s market reaction has been muted, with shares trading lower on the day of the announcement. A patent‑infringement lawsuit filed by Archer Aviation adds legal uncertainty, while competition from Joby Aviation and Archer remains intense.
“When you fly from Manhattan out to JFK, it will take about seven minutes to do the flight,” Simpson told Dezeen. “Then, when you land, a pilot jumps out, plugs in a charger, and Valo will recharge in seven to 10 minutes.” “We launch with four luxury business class seats,” he added, noting the frame can accommodate six helicopter seats, a unique feature in the market. “We designed this to be mass transport,” he said, highlighting the aircraft’s 100‑mile range and 150‑mph speed with zero emissions.
The battery pilot line’s activation is a strategic win that reduces integration risk and strengthens Vertical’s competitive moat, but the company’s financial pressures and legal challenges underscore the need for continued capital and disciplined execution as it moves toward commercial service.
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