Fri, 28 March, 2025
TWI is proud to announce our collaboration with Bristol-based Sora Aviation for the successful development of the first battery module prototypes for the Sora S-1, a next-generation electric vertical take-off and landing (eVTOL) aircraft. This partnership, supported by Innovate UK, marks a significant step towards the realisation of cost-effective, zero-emission aerial mobility solutions.
Sora Aviation’s proprietary battery pack design and aircraft integration technologies achieve industry-leading specific energy at the pack level, utilising existing in-production cells. TWI’s expertise in ultrasonic and laser welding was instrumental in ensuring the manufacturability and industrialisation of these high-performance battery packs, integrating advanced cell joining technologies early in the research and development phase.
Furqan, CEO of Sora Aviation, commented, “Integrating reliable, lightweight, and scalable battery pack technologies is essential to realising our vision of cost-effective and sustainable air mobility. Our partnership with TWI on ultrasonic and laser welding ensures that manufacturability and industrialisation of our battery packs are embedded early in the design process.”
Through rigorous testing and evaluation, TWI identified and optimised a laser welding process to ensure strong, high-integrity connections between battery cells. This approach enhances safety, reliability, and durability while maintaining the lightweight requirements critical for aviation applications.
Dr Abbasi Gandhi, Principal Project Leader at TWI and Project Manager for this collaboration, stated, “We are proud to collaborate with Sora Aviation in advancing battery technology for electric aviation. Our expertise in ultrasonic and laser welding has contributed to the safety and reliability of these battery modules, which are crucial for the next generation of sustainable air mobility.”
Necdet Capar, Senior Project Leader at TWI, added, “It was a pleasure to work with Sora Aviation on this pioneering project. Our welding expertise plays a crucial role in establishing scalable, high-precision laser welding processes, supporting the broader goal of sustainable and eco-friendly mobility solutions.”
The success of this project has been significantly bolstered by Innovate UK’s funding, which has accelerated research and development efforts in electric aviation.
TWI remains committed to supporting innovation in sustainable aviation and looks forward to further advancements in electric aircraft technology through continued research and collaboration.