Supernal and Umbra Group are entering into a continued partnership to leverage innovative technology that will enhance flight control operations in eVTOL vehicles. Umbra Group will supply actuators and motor control electronics needed to deploy a safe system architecture for Supernal's future vehicles, which the company plans to launch for commercial flights in 2028.

The collaboration aims to create new actuation standards, both for rotary and linear applications, that will deliver for advanced air mobility (AAM) manufacturers, that are concerned about size, weight, power, reliability and, most importantly, safety. Traditional rotary actuators use a gearbox connected to a power source that then operates an aircraft's flight control surface. Umbra Group's new line of actuators eliminates the use of the gearbox, making its product smaller, lighter and more efficient. Based on ball screws, this assembly can last for more than 20 years in commercial aircraft and is ideally suited for the AAM market where vehicles are often characterised by thin wings and limited component space.

“Supernal's approach is to drive innovation, not only at the aircraft level, but also at the system level,” says CCO Adam Slepian. “Umbra Group's actuation solutions will help us optimise our eVTOL vehicle design for maximum reliability in daily operations and enable advanced air mobility to reach the same levels of safety as the commercial aviation industry.”

Umbra Group brings unique capabilities in developing linear jam-tolerant actuators, which have a mechanism that can resolve a failure within an actuator and are a new solution in eVTOL vehicles. Supernal and Umbra Group's partnership marks the first time this type of technology will be integrated with electro-mechanical actuators (EMA), making them appropriate for primary and critical flight-control surfaces.

“This is a new and exciting challenge for Umbra Group. Becoming part of this project and being a supplier of advanced technologies for Supernal is an honour for us,” says CEO Matteo Notarangelo. “Being selected for the electromechanical implementation on such a revolutionary platform makes us proud and elevates us among the leading players in advanced air mobility. We strive for excellence in all vertical markets we serve, and we distinguish ourselves by offering innovative and sustainable solutions to our customers to help them become more competitive.”

In 2022, Umbra Group's actuator technology for rotary actuators earned the Airbus Helicopter Supplier Innovation Award.

This partnership is part of Supernal's vision to work with reputable suppliers that have a history of building aerospace-grade components, enabling the company to design safe, reliable and redundant systems for its aircraft; a key attribute for its 2028 entry into service.

Meanwhile Supernal and Qarbon Aerospace are forming a partnership to mature component welding techniques for future scaled production of eVTOL vehicles. As a leading manufacturer of composite components and assemblies for commercial and military aircraft and spacecraft, Qarbon Aerospace will work with Supernal to apply its induction welding technology to the assembly of the company's thermoplastic carbon composite 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.

“Supernal is thrilled to partner with Qarbon Aerospace to advance rate-enabling manufacturing processes for the advanced air mobility industry,” says Jaiwon Shin, president of parent company 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.”

With its ‘right product and right market at the right time’ approach, 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. In parallel, Supernal is working with Hyundai Motor Group to create a roadmap for integrating the automotive giant's automated manufacturing technologies into a scalable digital factory model, which will further reduce the cost and time of aircraft production.

“We are extremely excited that Supernal has selected Qarbon Aerospace's unique thermoplastic welding technology to enable the high-rate manufacturing of its eVTOL vehicle structure,” adds CEO Pete Wick. “Supernal's deliberate approach of carefully selecting and integrating rate-enabling technology from the start differentiates its 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.”

Supernal's partnership with Qarbon Aerospace is part of the company's ‘open ecosystem’ approach to address the niche technology needs of AAM. The company plans to grow its portfolio of manufacturing partners across other vehicle components, in addition to airframe.

Supernal and GKN Aerospace have commenced a partnership on the design and build of major aerostructures and electrical wiring interconnection system (EWIS). The companies will also mature high-rate manufacturing technologies to produce these parts and assembly methods.

GKN will supply lightweight aerostructures and high-voltage, high-power electrical wiring systems for Supernal's full-scale technology demonstrator, which the company will begin flying in 2024. The partnership aims to improve the business case and process for introducing advanced materials and rate-enabling assembly processes to the AAM industry. In working with GKN to mature these innovative processes from the outset, Supernal will develop volume ramp-up capabilities that enable the company to rapidly scale production as aircraft order demand grows.

“Manufacturing is crucial to the success of advanced air mobility, and Supernal is pleased to partner with leading suppliers, such as GKN Aerospace, to industrialise existing processes,” says Shin. “Instead of focusing on 'time to market,' Supernal is prioritising 'time to scale'. Our work with GKN Aerospace will lay the foundation for producing eVTOL vehicles at scale and will be bolstered by Hyundai Motor Group's high-tech manufacturing processes.”

As part of Hyundai Motor Group (HMG), Supernal is working to integrate the automotive leader's expertise, including supply chain management, logistics and distribution, and manufacturing, throughout the AAM ecosystem. In the manufacturing realm, HMG is helping Supernal to develop a scalable digital factory model that will industrialise aerospace material and assembly advancements. Supernal's work with leading aerospace manufacturers, such as GKN Aerospace, is an important first step toward the company's ability to reduce the cost and time of aircraft production.

GKN Aerospace is a global leader in the design and manufacturing of lightweight aerostructures and EWIS, across global original equipment manufacturers (OEMs) and the growing AAM market. Supernal and GKN Aerospace's design and manufacturing activities have begun at GKN Aerospace's Global Technology Centre in Bristol in the UK and across sites in Europe.

“We are excited to collaborate with Supernal and to support the development of this all-new eVTOL,” says John Pritchard, president, civil airframes, GKN Aerospace. “Supernal's eVTOL can play a key role in the transition to zero-emissions flight, and we are delighted to be collaborating on the platform in line with our mission to be the most trusted and sustainable partner in the sky. GKN Aerospace is proud to bring to this project its wealth of experience in design and high-rate manufacturing in conjunction with key technological innovations and expertise.”