Case Study: The FFLIP project

The future of electric aviation took a major step forward this week with the successful demonstration of the Future Flight and Land Infrastructure Programme (FFLIP) in Bicester, Oxfordshire.

Led by Petalite, this project showcased groundbreaking technology designed to power the next generation of electric vertical landing (eVTOL) aircraft, drones, and EVs.  The project is part of UKRI’s Future Flight Challenge, delivered by Innovate UK and the Economic and Social Research Council (ESRC).

Building the Foundation for eVTOL and Advanced Air Mobility (AAM)

The eVTOL industry, although in its’ infancy could transform transportation, enabling faster, cleaner, and more efficient air mobility. Advanced air mobility includes a wide range of applications across both urban and rural environments, offering the potential for regional and inter-city connectivity. However, without a reliable and scalable charging infrastructure, this vision cannot become a reality. Through collaboration and innovation, projects like FFLIP contribute to building the foundations of advanced air mobility – a completely new UK sector.

Project Objectives

The project aimed to develop technology within each consortium member to support the high-power demands of electrical aircraft and airport infrastructure of the future. The project focused on achieving design performance targets, sustainability objectives, and meeting end-user requirements.

At its conclusion, FFLIP delivered a full-scale, multi-modal demonstration integrating different forms of transport at a site in Oxfordshire. The aim was to validate the concept of a 600kW charger infrastructure with multiple power configurations, supporting the rapid, continuous charging of electric ground vehicles, trucks, drones, and eVTOL aircraft.

The Challenge

eVTOLs require ultra-rapid, high capacity charging to support their demanding duty cycles. The challenge is twofold: developing a 600kW charging solution capable of sustaining 24-hour operations while ensuring grid stability, energy efficiency, and cost-effectiveness.

An important hurdle is managing power demand fluctuations. High-density urban environments require infrastructure that can level peaks in demand through intelligent load management, preventing grid strain while ensuring continuous operation.  This was addressed by Petalite’s innovative charging technology.

Petalite’s Role

Pioneering EV Charging Technology

Petalite’s technology is well suited to the demands of eVTOL offering the reliability, scalability and availability required. Our patented Sinusoidal Direct Current (SDC) technology, built from the ground up, simplifies power supply design, enhances modularity, and delivers unmatched reliability. In the event of single power supply failure, the system experiences only a fractional loss in output.  Our novel methodology means we are not limited by the voltage source topologies found in existing charging technology on the market. 

By increasing the power density of our PowerCore from 12kW to 20kW over the course of the project, we improved both size and cost-efficiency. Additionally, transitioning from air to liquid cooling boosted efficiency and longevity, reducing maintenance demands.

In parallel, our team developed a prototype charge post and power hub designed with user experience in mind. Features such as active cable management ensures ease of use while maintaining high performance. Throughout the project, Petalite successfully met all technology milestones, advancing our Manufacturing Readiness Level (MRL) to 6 and Technical Readiness Level (TRL) to 7.

Consortium Members & Their Roles

• Petalite – Developed and tested a rapid charging solution for eVTOL and EV infrastructure.
• Oxfordshire County Council (OCC) – Provided the demonstration site and power supply, supporting the transition to zero-emission transport.
• Midlands Aerospace Alliance (MAA) – Ensured aerospace safety compliance and worked with the Civil Aviation Authority (CAA) to shape eVTOL charging regulations.
• ARC Aerosystems – Supplied eVTOL prototypes for real-world testing.

In addition SOS Synergy designed and installed the electrical infrastructure to support Petalite's prototype DC charge post and power hub, managed the associated civil engineering and the overall demo site.

Results

A Step Closer to Advanced Air Mobility (AAM)

As part of the project’s conclusion, Petalite’s prototype DC charge post and power hub successfully charged both an electric vehicle and a drone simultaneously. This demonstration validated the achievements of all consortium members and proved the viability of high-power, multi-modal charging infrastructure.

The demonstration site in Oxfordshire provided the perfect environment to showcase Petalite’s prototype power hub and charge post in real-world conditions. Within the available grid capacity, the system successfully charged an electric vehicle and a drone simultaneously. This practical test validated the concept of 600kW charging infrastructure with multi-power configurations designed for round-the-clock operation.

This demonstration represents a step forward in developing the charging infrastructure needed to support advanced air mobility in the UK.  Projects like FFLIP provide a glimpse into the future and help explore the potential for high-power, scalable charging solutions that could support future autonomous air logistics, air taxis, and next-generation aviation.

A Vision for the Future

Petalite’s CTO, Robert Nash, reflects on the achievement: