On March 18, 2026, Vertical Aerospace announced the launch of a pilot battery production line to support assembly of its VALO electric vertical takeoff and landing (eVTOL) aircraft. The new line is located at the company’s manufacturing facility in Gloucestershire, UK, and marks a significant step toward in-house production of the bespoke high-energy battery systems that will power VALO.
The pilot line features a modular, semi-automated manufacturing cell capable of processing individual battery modules. Key processes include precision welding and trimming of prismatic cells, application of thermal interface materials, and automated assembly of enclosures and interconnect wiring. Integrated digital inspection systems capture real-time data at each stage, enabling robust quality control and full traceability for every module.
Vertical Aerospace will use the line to qualify production methods, validate its thermal management solutions, and conduct early life-cycle testing under realistic operating conditions. The VALO battery system is designed around a high-nickel cathode chemistry targeting an energy density of 260 watt-hours per kilogram at the pack level. Each module incorporates an advanced battery management system (BMS) that monitors cell voltage and temperature, optimizing charge-discharge cycles to enhance safety and longevity.
Following pilot-line validation, the company plans to scale up production in its forthcoming mass-manufacturing facility ahead of VALO’s planned commercial rollout in 2028. Establishing the pilot line is a key part of Vertical Aerospace’s strategy to maintain direct control over critical powertrain components, reduce certification risk, and accelerate the development timeline.
According to CEO Stephen Fitzpatrick, this capability strengthens the company’s vertical integration and positions it to deliver a certified, high-performance eVTOL aircraft to the market.
Source: Business Wire
