Evio and ElringKlinger launch prototype build for EVIO 810 energy storage system

Evio and ElringKlinger have launched prototype build of the full-scale battery pack for the Evio 810 Energy Storage System (ESS), marking a key milestone in the development of the aircraft's strong-hybrid propulsion system. The prototypes will support initial pack-level testing and validation as the programme progresses through its next phase of development.

The milestone follows multi-physics pack engineering, detailed cell characterisation and progress in physical multi-cell thermal runaway testing. Together, these activities have established a mature design baseline intended to meet the Evio 810's performance requirements while aligning with applicable Part 25 airworthiness specifications and evolving battery safety guidance.

"Moving into full-scale prototype builds is an important step in the development of the Evio 810 Energy Storage System," said Luc Van Bavel, Chief Technology Officer and co-founder of Evio. "It reflects the significant design and validation work completed to date and the complementary expertise our teams bring to the program, as we progress the validation of the Energy Storage System at pack level."

Evio and ElringKlinger entered into collaborative agreements earlier this year to define, develop, prototype and test the Evio 810 ESS. The collaboration combines ElringKlinger's more than 20 years of alternative powertrain R&D and over a decade of Energy Storage System production experience with Evio's expertise in aircraft design, hybrid-electric propulsion, systems integration and certification.

"This collaboration demonstrates the successful application of our battery solutions beyond the automotive sector," said Juergen Weingaertner, Senior Vice President Battery Technology at ElringKlinger. "ElringKlinger's experience and engineering capabilities in battery design and manufacturing, together with Evio's aerospace expertise, have resulted in an innovative energy storage system with outstanding energy density and advanced safety features. This milestone further demonstrates the versatility of our battery technology in emerging mobility markets."

The ESS is a critical component of Evio's proprietary strong-hybrid propulsion architecture, enabling all-electric operation on short missions and around airports, while combining electric and conventional propulsion for longer missions. This flexibility is designed to reduce fuel consumption, emissions and noise while also supporting a broader range of mission applications.

The full-scale prototype packs will support initial pack-level testing as Evio continues development of the Evio 810's integrated propulsion system. The prototypes will leverage Molicel's latest cell technology, combining world-class safety and energy density with the performance, reliability, and safety requirements of the Evio 810.