Hybrid Power Onboard: DAIR helps Horizon Aircraft transform the way we fly
The DAIR Green Fund has proven to be a vital resource to small- and medium-sized enterprises (SMEs) in accelerating innovation forward within southern Ontario’s aerospace sector. The Green Fund supports SMEs in achieving a higher technology readiness level (TRL) with eventual commercialization and fostering partnerships with industry leaders and/or academia. Downsview Aerospace Innovation & Research (DAIR), which operates from Downsview Park in Toronto, Ontario, is a not-for-profit consortium, which energizes the innovation ecosystem by bringing together start-ups and high-potential businesses with leading aerospace companies and post-secondary institutions. The need and interest for such an initiative has been recognized by SMEs who applied in masses to this selective program, which is supported by the Government of Canada through the Federal Economic Development Agency for Southern Ontario (FedDev Ontario). Horizon Aircraft is on a journey to revolutionize how people and goods can be moved worldwide with groundbreaking hybrid power onboard a transformational aircraft. In collaboration with DAIR and the support of the DAIR Green Fund, Horizon Aircraft’s CEO, Brandon Robinson, is leading the charge of a new and exciting sector within aerospace which will transform the future of flight. Robinson began the journey with the DAIR team in 2022, starting a project to develop an advanced hybrid electric power system for Horizon’s prototype aircraft. The vertical take-off and landing (VTOL) aircraft has the controls of a helicopter with the efficiency to fly at the speed of a traditional aircraft. Horizon’s innovative hybrid power system onboard the proprietary VTOL will introduce more efficiency enroute and extend flight duration beyond conventional aircraft that stop to refuel. The VTOL aims to offer the flexibility to recharge itself during flight or on the ground after completing its tasks. The result is a significant reduction in emissions, leading the way for new access to flights and locations with a more sustainable approach to transportation. Horizon Aircraft’s unique hybrid electric VTOL concept, built upon patented ducted fan-in-wing technology, sets it apart from its competitors. This cutting-edge technology allows the aircraft to fly faster and farther and carry heavier payloads with agile controls for vertical take-off and landing, revolutionizing air mobility. With a design that enables the aircraft to operate like a standard aircraft for 98% of its mission, Horizon’s VTOL represents the pinnacle of safety, sustainability, durability, and operational versatility. The support from the DAIR Green Fund reaffirms the immense potential of Horizon Aircraft’s innovative technologies, which will be showcased in their newly announced seven-seater “Cavorite X7.”. As the global urban air mobility market is projected to exceed $30 billion by 2031, Horizon is poised to lead the industry with its visionary approach and expertise whilst growing a greener economy that nurtures green jobs for the future. With a team that boasts almost a century of experience building aircraft and over 25,000 hours of flying time, Horizon Aircraft is at the forefront of aviation and aerospace innovation. Horizon’s electric motor and battery technology advancements are essential to realizing this vision. In the past, the limitations of battery technology hindered practical designs in both the automotive and aerospace sectors. Recent advances in lithium-ion and lithium-sulfur battery commercialization have dramatically improved power densities, making them viable for aircraft design applications, particularly when coupled with a hybrid power system. Horizon Aircraft stands uniquely positioned to harness the benefits of these cutting-edge technologies. Developing the novel power architecture comes with challenges. The Horizon team began their DAIR Green Fund project by identifying and evaluating architectural options for their advanced hybrid electric power system. The team has faced technical obstacles head-on, from managing electromagnetic interference to understanding heat dissipation and addressing electrical power distribution complexities. Their perseverance is driven by the possibilities of in-flight and on-ground charging, unlocking flight horizons across urban centres and to small and rural communities that have been inaccessible and remote in the past. Horizon Aircraft’s hybrid electric VTOL introduces unprecedented opportunities to connect people and products in hard-to-reach locations, such as northern, remote, rural, and isolated communities. The aircraft has the potential to save lives, whether cutting medical evacuation mission times in half compared to traditional helicopters, or efficiently delivering essential goods such as life-saving organs and critical cancer drugs. With new perceptions of regional travel and delivery, this hybrid-powered VTOL aircraft creates a cleaner and greener option for the economy. Horizon Aircraft is an innovation-led growth team who thrives on pushing boundaries to create an aircraft that makes a real difference in Canada and around the globe. As they fine-tune and integrate the core power system, the advancements made under this program could find broader applicability in the global Advanced Air Mobility market and other sectors. In January 2024, Horizon took its company public to the NASDAQ Stock Exchange. With the success of its Green Fund project and many others through the years, Horizon is proving to everyone the successes that can be achieved within the Ontario region by developing valuable partnerships and collaborations along the journey. “The support from DAIR’s Green Fund accelerated our plans to develop an advanced hybrid electric VTOL using a greener sustainable power system. Together, Horizon Aircraft and DAIR are transforming the global aviation and aerospace sector. The horizon is bright – we are proud to be on this transformative journey to redefine the future of flight.” Brandon RobinsonCEO, Horizon Aircraft
Burloak Develops 3D Printing of Tungsten
As a leader in additive manufacturing, Burloak is a business that truly understands the importance of innovation. Our commitment to innovation has enabled us to push boundaries and develop novel processes, like becoming one of the only additive manufacturing companies in North America that can 3D-print tungsten for production applications. Tungsten’s density and extremely high-melting point make it very difficult to manufacture conventionally but makes it a perfect fit for additive manufacturing. With its unrivaled material properties, tungsten is the ideal material for a range of unique applications that includes cathodes, radiation shielding, counterweights, projectiles, and other aerospace and defense applications. “Developing the process to 3D print and post-process a new alloy can be very challenging and take a very long time,” says Keyvan Hosseinkhani, Burloak’s Technical Director. “Our team of subject matter experts coupled with our in-house 3D printing, heat treatment, and material testing capabilities give us the ability to take on challenging applications like the development of tungsten printing at a much faster rate than most.” The tungsten printing process development was funded by the Downsview Aerospace & Innovation Research (DAIR) Green Fund, which provides financial support for collaborative R&D projects that can demonstrate a significant impact on sustainability in the aerospace industry. The DAIR Green Fund project is supported by the Government of Canada through the Federal Economic Development Agency for Southern Ontario (FedDev Ontario). “3D printing is a key manufacturing technology that is part of the aerospace industry’s push towards improved sustainability,” says Steven Cargnello, DAIR Green Fund Manager. “If we can expand on the types of materials that can be 3D printed, this will enable more companies to leverage the technology to reduce their environmental footprint and ultimately help them achieve their sustainability goals.” In traditional manufacturing, components are often created by removing raw material from a block of metal to achieve the desired form. By contrast, additive manufacturing technologies use a cutting-edge process to sinter metal powder to build 3D components layer-by-layer – using only the necessary material to create the desired part. One of the more exciting benefits of additive manufacturing is the ability to print a part at near-net shape, eliminating or significantly reducing the amount of post-processing needed without compromising on strength. With tungsten being such a difficult material to machine, the advantages of 3D printing tungsten can help companies meet their sustainability objectives by reducing waste while improving cost and performance. With support from DAIR’s Green Fund, Burloak is leading the way in offering greener and more efficient solutions for complex manufacturing challenges. “Developing the process to 3D print and post-process a new alloy can be very challenging and take a very long time. Our team of subject matter experts coupled with our in-house 3D printing, heat treatment, and material testing capabilities give us the ability to take on challenging applications like the development of tungsten printing at a much faster rate than most.” Keyvan HosseinkhaniTechnical Director, Burloak Technologies
Brampton Processing takes the lead in sustainable aerospace coatings with DAIR partnership
Brampton Processing is partnering with Downsview Aerospace Innovation & Research (DAIR) on an ambitious project to revolutionize the industry’s approach to protective coatings for the aerospace sector. Led by Alex Cajic, Vice President of Business Development at Koss Aerospace and Brampton Processing, the project aims to introduce sustainable and environmentally responsible processes that will significantly reduce global aviation emissions. DAIR, a non-profit consortium operating from Downsview Park in Toronto, energizes the innovation ecosystem by bringing together start-ups and high-potential businesses such as Brampton Processing with leading aerospace companies and post-secondary institutions. Through the DAIR Green Fund, the organization has joined forces with Brampton Processing to advance technology readiness and support a regionally significant project to reduce emissions and the environmental footprint of the aerospace industry. This partnership offers funding and expertise to ensure Brampton Processing can evolve advancing traditional methods towards a cleaner, greener, and more sustainable process for the aerospace manufacturing in Ontario. Established in 1999, Brampton Processing specializes in state-of-the-art metal processing and finishing solutions. Their cutting-edge facility, located minutes from Toronto Pearson International Airport, houses advanced technology and employs experienced professionals dedicated to meeting the industry’s stringent requirements. As a responsible partner to significant players in the aerospace sector, including flagship customer Bombardier and other tier 1 companies like Airbus and Boeing, Brampton Processing recognizes the importance of transitioning the sector with new, modern, environmentally friendly technologies and processes. By replacing harmful compounds with less toxic alternatives, the company will reduce its environmental footprint and emissions while ensuring the highest quality for its customers. Through investments in new processes and obtaining additional industry approvals, Brampton Processing will expand its range of finishing services, thus creating sustainable and green jobs for the future, ultimately strengthening Ontario’s position in the aerospace industry. This project will help address bottlenecks many industries face in metal finishing by introducing environmentally friendly processes and increasing capacity to the satisfaction of employees and its primary customers. With the support of its skilled team and the guidance of tier 1 customers and suppliers, Brampton Processing is seamlessly integrating changes and obtaining approvals from key industry players. The company is introducing new processes without disrupting its high-quality customer service with current customers. Successful execution of the project will solidify Brampton Processing’s position as a leader in aerospace coatings, driving new clean company growth and contributing to a robust economy regionally through sustainable and green employment opportunities, enhanced competitiveness, and a focus on delivering the highest quality sustainable products. Brampton Processing’s commitment to a greener economy aligns with the global shift towards sustainability. By eliminating toxic hexavalent chromium compounds in its manufacturing processes and adopting more environmentally friendly alternatives, Brampton Processing plays a vital role in shaping a more eco-friendly and prosperous aerospace sector. “DAIR’s Green Fund is helping drive Brampton Processing’s commitment to sustainability, our goal is to eliminate hexavalent chrome from all our special processes. We are immensely grateful for this support, as it not only enhances our commitment to environmental responsibility but also ensures a greener, and more sustainable future for our industry.” – Alex Cajic, VP Business Development, Brampton Processing By prioritizing sustainability, Brampton Processing sets itself apart by working to eliminate toxic hexavalent chromium compounds from its manufacturing processes. With support from DAIR and collaboration with industry and academic leaders in the ecosystem, Brampton Processing is well on its way to achieving its goals and securing a cleaner future for the aerospace sector. Through this initiative, the company will seize growth opportunities, strengthen its position, fortifying its competitive edge and contributing to a cleaner economic growth regionally and globally. “DAIR’s Green Fund is helping drive Brampton Processing’s commitment to sustainability, our goal is to eliminate hexavalent chrome from all our special processes. We are immensely grateful for this support, as it not only enhances our commitment to environmental responsibility but also ensures a greener, and more sustainable future for our industry.” Alex CajicVP Business Development, Brampton Processing
DAIR Partnership Helps Solid UltraBattery Advance High-Energy Density Green Battery
Solid Ultrabattery is making strides to revolutionize the battery industry. Led by inventor and entrepreneur V-Bond Lee and founder Dr. Zhongwei Chen, the company has partnered with Downsview Aerospace Innovation & Research (DAIR) to advance the development of low-cost, high-energy, solid-state green batteries for the rigorous demands of aerospace applications. DAIR, a non-profit consortium operating from Downsview Park in Toronto, energizes the innovation ecosystem by bringing together start-ups and high-potential businesses such as Solid Ultrabattery with leading aerospace companies and post-secondary institutions. Through the DAIR Green Fund, they share a common goal of advancing technology readiness, accelerating innovation-led growth, developing cutting-edge sectoral technology, and supporting projects that aim in greening the economy through reduced aviation emissions. CEO V-Bond Lee brings a wealth of experience to the project. He has successfully developed and commercialized groundbreaking methods and technologies for various industries, including aerospace, automotive, and infrastructure components. Zhongwei Chen, Ph.D., a professor in the department of Chemical Engineering at the University of Waterloo, dedicates his expertise in battery and fuel cell technology to the team. With funding and support from the DAIR Green Fund, Solid UltraBattery is advancing its plans to develop a lightweight 5Ah single-cell pack as a prototype to be validated with its use on a small drone. Reaching this Technology Readiness Level (TRL) 7 before the project’s completion will also help the company advance its goals to develop an all-solid-state battery by 2030. “The DAIR Green Fund has provided Solid Ultrabattery with a distinct opportunity to progress its energy storage technology towards commercialization in the aerospace industry. We are highly satisfied with the project’s current progress and the valuable support and networking opportunities facilitated by DAIR.” V-Bond Lee, Chief Executive Officer, Solid Ultrabattery The support and funding from DAIR have been instrumental in the company’s journey to support the development of new aerospace sectors and revolutionize the battery industry to provide a clean and sustainable economy. Green batteries offer increased performance with better energy efficiency, greater energy density, and longer life cycles while reducing weight onboard. The Solid UltraBattery innovation introduces a green battery less prone to fire and explosion than conventional batteries, making them safer to use and transport in aerospace applications while providing a greener future. Green batteries have significant potential to help the aerospace sector reduce its environmental impact toward meeting its global sustainability goals. The green batteries can be used as the power source for drones to support a range of applications, from surveillance and sensing to logistics and transportation. Whether powering electric propulsion systems for an aircraft or storing energy generated from renewable sources, green batteries can efficiently release energy during flight, support high-speed and more prolonged flights for emergencies or power equipment on the ground, reducing or eliminating the need for fossil fuel combustion engines. Solid UltraBattery’s solid-state green batteries can address a growing demand for safe, lightweight, high-performance batteries. In aerospace, new sectors such as drones are widely used for surveillance and reconnaissance purposes to provide real-time aerial views, gather intelligence, and monitor areas that are difficult or dangerous for humans to access. This sector can provide a platform for innovation-led businesses to test, refine, and validate cutting-edge new technologies in a cost-effective and controlled manner. The Solid UltraBattery team is well-equipped to develop and commercialize groundbreaking solid electrolyte green battery technology. With a 10,000 ft2 state-of-the-art facility in Guelph, Ontario, the company has cutting-edge prototype and test equipment to uphold R&D accuracy and efficiency. Recently built in Scarborough, Ontario, the company’s prototype lab has additional fabrication and cycle test equipment ready for high-quality, high-quantity battery-grade anode production, and ready to create sustainable green jobs once commercialized. In partnership with DAIR, Solid UltraBattery is positioned as a leading company in the energy storage industry and primed to scale-up their business to new heights. Their advancements in high-energy-density green batteries have significant sustainable potential for the aerospace sector and the economy. Focused on R&D, design, and production of cutting-edge solid-state green batteries, the team has set their sights on customers in military and security, offering energy-dense green batteries ideal for fire and rescue, coast guard, and search missions. Solid UltraBattery is poised to shape the future of energy storage technology. The company’s development of low-cost, high-energy, and safe solid-state batteries with high energy density has significant potential to lead the energy storage industry and produce clean energy for a greener economy. With the support of partners like DAIR and their unwavering commitment to accelerating innovation-led growth, the company is leading the way for a cleaner, greener, and more sustainable future. “The DAIR Green Fund has provided Solid Ultrabattery with a distinct opportunity to progress its energy storage technology towards commercialization in the aerospace industry. We are highly satisfied with the project’s current progress and the valuable support and networking opportunities facilitated by DAIR.” V-Bond LeeChief Executive Officer, Solid Battery
HEBE Network: Innovative Partnership in Clean Hydrogen Storage Revolutionizes the Aerospace Sector
The DAIR Green Fund has proven to be a vital resource to small- and medium-sized enterprises (SMEs) in accelerating innovation forward within southern Ontario’s aerospace sector. The Green Fund supports our SMEs in achieving a higher technology readiness level (TRL) with eventual commercialization and fostering partnerships with industry leaders and/or academia. The need and interest for such an initiative has been recognized by SMEs that applied in masses to this selective program, which is supported by the Government of Canada through the Federal Economic Development Agency for Southern Ontario (FedDev Ontario). Enzo Cavaliere is on a remarkable journey to revolutionize the aerospace sector with clean hydrogen storage innovation. As founder and CEO of HEBE Network, Cavaliere is using his passion for technology and engineering to realize a greener and more sustainable economy. This ambition has been made possible through the HEBE Network partnership with Downsview Aerospace Innovation & Research (DAIR). DAIR, a non-profit consortium operating from Downsview Park in Toronto, Ontario, energizes the innovation ecosystem by bringing together start-ups and high-potential businesses such as HEBE with leading aerospace companies and post-secondary institutions. Through the DAIR Green Fund, they share a common goal of accelerating innovation-led growth by advancing technology readiness and supporting transformative companies with a goal of greening the economy by reducing aviation emissions. The HEBE mission is bold: to become the leading provider of underground, purpose-built, pressurized zero carbon hydrogen storage at scale. With the DAIR Green Fund, the HEBE team is proactively solving hydrogen infrastructure problems by developing an accessible, green hydrogen storage solution that is three to five times more cost-effective, has an 80 percent lower carbon footprint, and is significantly safer than conventional industry practices. Notable progress in renewables, electrification of mobility and lithium battery energy storage over the previous 10 years, has invigorated industry to look at large investments in hydrogen technology because it is widely accepted for its extraordinary potential to make a substantial impact on greening our economy, and it can be implemented across all sectors. The HEBE initiative is focused on introducing a safer, simplified, green hydrogen production process worldwide. Globally, green hydrogen adoption requires continued cost reductions in renewables (solar and wind), significant investment in the mass commercialization of electrolysers, and innovations in the process of ‘storage of pressurized hydrogen’. HEBE is intent on disrupting the legacy carbon steel or composite hydrogen cylinder marketplace with its proprietary HEBE CELL ‘vaults’, made of an epoxy and aggregate mixture, providing a cheaper solution that enables scaling and offers a significantly safer design. Multiple ‘vaults’ can be networked to create more power as required. The DAIR Green Fund supports the development of HEBE’s groundbreaking clean technology over several phases. In the initial phase, HEBE focused on designing, testing, and analyzing the HEBE Cell pressure vessel prototype. With funding from DAIR, HEBE is actively working with partners to develop and test the minimum viable product (MVP) of its storage system. The team is set on validating a safer, simplified, green hydrogen production process and storage system with less environmental impact, improved land use, and significantly lower costs than found in today’s market. The team targets a TRL 7 by the end of the project. By assessing the performance and reliability of the innovative green hydrogen storage solution, the HEBE Network aims to prove the solutions’ feasibility and pave the way for its commercialization into multiple sectors. HEBE is looking to integrate its underground storage solution with renewable energy, electrolysis, and fuel cells, to create a fully integrated hydrogen fueling station of the future. By avoiding mechanical compression and conventional storage materials, HEBE has set itself apart in the market. HEBE aims to reduce capital and operating expenditures to safely produce and store green hydrogen, remove the constraints of hydrogen storage hubs, and decrease the land footprint needed for above-ground storage stations. With successful prototype testing and ongoing collaboration with a manufacturing partner, HEBE is validating its ability to scale the solution at a reasonable cost. In a future where fully integrated electric vehicle (EV) and hydrogen fueling stations would utilize HEBE’s proprietary underground storage, the long-term outlook is promising. Armed with determination, partnerships, and the support of the DAIR community, Cavaliere and the HEBE Network team are confident they will play a vital role in shaping a greener and more sustainable economy. “Working with DAIR has been incredibly positive for our company. As a young company, bootstrapping to where we are now has been great – with the Green Fund we have reignited the mission, formed new partnerships and advanced our prototyping of the technology towards achieving TRL 7. We’re rapidly putting the HEBE Cell through its design phases for the global green market to positively impact our environment.” Enzo CavaliereFounder & CEO, HEBE