- Helix develops a three-step architecture to overhaul the propulsion systems of sub-250NM aircraft, reducing their fuel burn per flight to just 23.9kg.
- New architecture combines a series hybrid powertrain, a geared high-density electric propulsion unit, and ducted fan propulsors
Milton Keynes, UK, [12.06.2025] – Helix (a trading name of Integral Powertrain Ltd), the UK manufacturer of the world’s most power-dense electric motors and inverters, has today unveiled a blueprint for reducing fuel burn in very short-haul flights by 90%.
In the company’s new white paper, “A New Architecture for Aviation,” Helix sets out a three-step architectural overhaul for regional airliners and private aircraft. With each step drawing upon proven and readily available technology, the resulting architecture allows for a radical reduction in fuel burn and emissions for flights of ranges up to 250 nautical miles.
One in every four flights worldwide is currently very short-haul, with the route category well-positioned to help mitigate capacity challenges facing infrastructure and airports. Helix’s new architecture resolves the major challenge facing the segment: its higher relative fixed costs and fuel burn. It achieves this by:
- Adopting a series hybrid configuration, enabling the cruise phase of the flight to be entirely powered by a pre-charged ~770kWh battery. This alone reduces fuel consumption by 74.3%.
- Using a geared, high-density electric propulsion system that can unlock significant weight savings by delivering more thrust for less mass. This unlocks a further 4% saving in fuel consumption.
- Replacing propellers with ducted fans to improve thrust efficiency. This provides a final 10.4% reduction in fuel consumption.
Altogether, this architecture reduces fuel burn per flight to just 23.8kg – just 10.3% of a conventional aircraft. All these technologies are currently available to manufacturers and operators, providing an immediate solution to the aviation industry’s fuel and decarbonisation challenges.
Helix’s new architecture addresses the scrutiny faced by the very short-haul segment around its carbon-intensity, with these routes currently generating over 155g of CO2 per passenger kilometre – 75% more than the industry average. This new architecture completely up-ends this position, transforming very short-haul aviation into the least fuel- and emissions-intensive segment in aviation.
Along with the ecological value, these technologies also promise to make very short-haul flight much more cost competitive. Fuel currently makes up nearly 30% of airline operational costs, which is set to rise significantly as the industry seeks to reduce its emissions. One of the major drivers is the industry’s commitment to alternative fuel options: sustainable aviation fuels can currently cost many multiples of traditional fossil fuels. By reducing the fuel consumption of very short-haul by a factor of ten, the new architecture catapults the unit economics of very short-haul towards the top of the industry.
Derek Jordanou-Bailey, Aerospace Chief Engineer at Helix, said, “Through an order-of-magnitude reduction in fuel costs, the vehicle architecture we’ve outlined delivers extremely economic operating conditions for very short-haul flights. This could shift these routes to having the very lowest cost per available seat kilometre in the industry and help encourage the adoption of sustainable, regional air travel. We believe that aviation needs to decarbonise as soon as possible, which is why we’ve developed an architecture that relies on currently available technology—this is a solution for today.”
For this project, the Helix team drew upon its world-class experience in electrified propulsion—particularly as the manufacturers of the most power-dense motors available on the market. This has engendered a visionary, full-system perspective of aerospace electrification among the Helix team, which in turn inspired the development of the new architecture.
Download “A new architecture for aviation: Reducing very short-haul fuel burn by 90%” here.
