Santa Ana, CA, October 29, 2022 - Tier 1 Engineering, in cooperation with its collaborator Lung Biotechnology PBC, announced today it had successfully completed a flight between Jacqueline Cochran Regional Airport, near Coachella, and Palm Springs International Airport on October 29, 2022 at 1100 PST, the first helicopter flight between airfields solely by electric power. The flight from Jacqueline Cochran to Palm Springs equals the 21nm distance of the first commercial helicopter flight across the English Channel on September 25, 1947. The all-electric aircraft is a modified Robinson R44 helicopter flown by pilots Ric Webb of OC Helicopters and Martine Rothblatt of Lung Biotechnology.

Glen Dromgoole, President of Tier 1 Engineering, said, "Progress in the development of all-electric propulsion is similar to other periods of significant advance in aviation. The first aircraft flew short distances and many people were afraid to ride in the new flying machines. At the start of the Jet Age, there was widespread skepticism about the commercial viability of the turbine engine. Today’s historic flight demonstrates the potential of all-electric rotorcraft and we are thrilled by this achievement."

The e-R44 uses a novel quick-swap technology for its helicopter battery packs to enable return trip flights without waiting for a recharge. The time required to swap a battery pack is 15 minutes vs 1 hour for a full recharge. The specific cross-country route for today’s historic flight was chosen based upon FAA approval.

"These flights are the building blocks that lay the foundation where our future can continue to soar. I am excited and honored to be part of this amazing team, this historic event and furthering the advancement of making blue skies green™," said pilot Ric Webb, CEO of Part 135 helicopter operator OC Helicopters, which is planning to offer organ delivery services via the electric R44.

Dr. Martine Rothblatt, one of the helicopter’s pilots and the CEO for of parent company United Therapeutics Corporation, said "Lung Biotechnology is committed to delivering life-saving transplantable organs with a zero-carbon footprint. It is fully possible to save patients’ lives while ensuring a livable planet. Today’s historic inter-city electric helicopter flight demonstrates that many organ transport distances are doable with electric aircraft using today’s technology. We are committed to achieving FAA certification of this electric helicopter and to using newer energy cells to extend our ranges to hundreds of miles in the next few years," concluded Dr. Rothblatt.

The 3rd Generation all-electric e-R44 is designed to deliver manufactured organs for transplant by United Therapeutics, the biotechnology company responsible for the world’s first transplant of a genetically-modified pig heart into a human patient, and for creating the world’s first full-size 3D bio-printed organs. United Therapeutics plans to use electric and sustainable aviation fueled fixed-wing aircraft to deliver transplantable organs long distances to airports and then to use the electric helicopters and eVTOLs for the shorter hops such as from the airports to the transplant hospitals. In October 2021, Unither Bioelectronics, a United Therapeutics subsidiary, accomplished the world’s first delivery of a lung for transplant by electric drone between two hospitals in downtown Toronto.

Original Story: http://tier1engineering.com/news/tier-1-engineering's-3rd-generation-electric-helicopter-achieves-historic-airport-airport-cross

Tier 1 Engineering, October 29, 2022 | Photo by Dan Megna Photography

In a historic first, a fully electric-powered Robinson R44 helicopter flew from one airport to another. The 21-nm flight took place on Saturday at 11 a.m. local time from Jacqueline Cochran Regional Airport in Thermal, California, to Palm Springs International Airport. The electric R44 flight was flown by OC Helicopters CEO Ric Webb and Martine Rothblatt, CEO of Lung Biotechnology parent company United Therapeutics.

Tier 1 Engineering and Lung Biotechnology are collaborating on the electric R44 project. The plan is to use electric-powered helicopters and eVTOLs for delivery of transplantable organs on short-distance flights from airports to hospitals after the organs are delivered by electric and sustainable-fuel-powered fixed-wing aircraft to airports near hospitals.

This version of the electric R44 is the third-generation design of the R44 electric-propulsion system. It features a quick-swap battery back that can be changed in 15 minutes or charged in one hour. Plans call for FAA certification of the R44 electric-propulsion system and development of "newer energy cells" that will extend range to hundreds of miles, according to Rothblatt.

"Lung Biotechnology is committed to delivering life-saving transplantable organs with a zero-carbon footprint," she said. "It is fully possible to save patients’ lives while ensuring a livable planet. Today’s historic inter-city electric helicopter flight demonstrates that many organ transport distances are doable with electric aircraft using today’s technology."

Original Story: https://www.ainonline.com/aviation-news/general-aviation/2022-10-31/electric-r44-completes-first-airport-airport-flight

AIN Online by Matt Thurber - October 31, 2022 | Photo by Dan Megna Photography

Tier 1 Engineering announced that it has successfully completed an airport-to-airport flight with its all-electric helicopter design. The aircraft, a modified Robinson R44, flew between California’s Jacqueline Cochran Regional Airport (TRM) and Palm Springs International Airport (PSP) on Saturday. The company is calling the trip "the first helicopter flight between airfields solely by electric power."

"Progress in the development of all-electric propulsion is similar to other periods of significant advance in aviation," said Tier 1 Engineering President Glen Dromgoole. "The first aircraft flew short distances and many people were afraid to ride in the new flying machines. At the start of the Jet Age, there was widespread skepticism about the commercial viability of the turbine engine. Today’s historic flight demonstrates the potential of all-electric rotorcraft and we are thrilled by this achievement."

Tier 1 Engineering reported that the flight was conducted in collaboration with medical research and development company Lung Biotechnology. The aircraft that flew on Saturday is Tier 1’s third-generation "e-R44," which the company says was designed to "deliver manufactured organs for transplant" by Lung Biotechnology parent company United Therapeutics. According to Tier 1, the model uses quick-swap battery technology that allows battery packs to be changed in 15 minutes.

Original Story: https://www.avweb.com/aviation-news/electric-r44-completes-first-flight-between-airfields/

AVWeb By Kate O’Connor - October 31, 2022 | Photo by Dan Megna Photography

Tier 1 Engineering, in collaboration with Lung Biotechnology PBC, successfully completed the first all-electric cross-country helicopter flight along the scenic Coachella Valley of California on Oct. 29, 2022.

The third-generation battery-electric e-R44 conversion of the popular Robinson R44 helicopter was piloted by Ric Webb, CEO of part 135 charter operator OC Helicopters, and Dr. Martine Rothblatt, CEO of United Therapeutics. The aircraft was outfitted with a 50-pound (23-kilogram) payload to simulate a transplant organ care system in the rear cabin.

The helicopter took off from Jacqueline Cochran Airport (KTRM) and landed at Palm Springs International Airport (KPSP) at 11:11 a.m., covering the FAA-approved 24-mile (39-kilometer) route in a flight time of 20 minutes.

The e-R44 was greeted by dozens of guests invited to Palm Springs Airport by Tier 1 Engineering and United Therapeutics, the project sponsor, to witness the historic occasion.

"This was the first ever electric helicopter flight between two cities and between two airports," said Rothblatt, adding that it demonstrated "it is practical to deliver transplantable organs by electric helicopters from hospital to hospital."

Glen Dromgoole, president of Tier 1 Engineering, said the e-R44 is capable of flying 20-minute trips "with a good reserve," noting the battery cells had a 50 percent state of charge (SOC) on landing.

"We believe we’re developing a really practical solution for short duration rotorcraft flights such as organ deliveries, pilot training, scenic tours and other inner-city trips," he said.

Dromgoole noted that major achievements in aviation often start with flying short distances, such as the first non-stop airplane flight across the English Channel in 1909 and the first commercial helicopter flight in 1947, which covered a similar flying distance to this flight with the e-R44.

Original Story: https://verticalmag.com/news/tier-1-engineerings-electric-e-r44-makes-historic-airport-to-airport-cross-country-flight

Vertical Magazine By Ken Swartz - November 2, 2022 | Photo by Dan Megna Photography

An accomplished fixed-wing and helicopter pilot, Rothblatt started researching the feasibility of electric vertical flight about six years ago and shared the specifications of zero-emissions electric rotorcraft with a number of aerospace companies to launch a research project.

Dromgoole was the first person to positively respond to Rothblatt’s line of inquiry. Tier 1 Engineering received a contract in early 2016 to rapidly build and fly a proof-of-concept electric helicopter.

UT subsidiary Lung Biotechnology purchased a 2006 model R44 Raven II (registration N3115T) for about $300,000. Dromgoole’s team removed the aircraft’s bulky 260-hp Lycoming IO-540-AE1A5, which weighed about 500 lb. (225 kg), including accessories, as well as the complete fuel system.

The engine and fuel system were then replaced with an electric propulsion system primarily sourced from the automotive industry, including two early YASA P400HC electric motors (stacked in parallel and powered by separate inverters), lithium polymer batteries made for the Brammo electric motorcycle, inverter/motor controllers made by Formula 1 hybrid-electric supplier Rinehart Motion Systems, and a reduction gearbox made by Autoflight.

The YASA motor was light enough to install by hand and could achieve the rated power required for the R44, producing peak shaft power of 183 kW (245 hp) for five minutes and continuous shaft power of 153 kW (205 hp).

Webb made the first successful hover of the first-generation e-R44 at Los Alamitos Army Airfield (KSLI) on Sept. 13, 2016, its first hover-taxi the following day, and a record five-minute cruise flight on Sept. 21, which drained approximately 20 percent of the battery energy.

On Feb. 16, 2017, Tier 1 Engineering established a series of world records for "duration, altitude, payload, weight and speed of battery-powered rotorcraft or helicopter flight" at Los Alamitos Army Airfield, six miles (9.6 kilometers) east of Long Beach Airport.

The flight lasted 30 minutes, reached 800 feet (244 meters) and a peak speed of 80 knots (148 km/h) with an eight percent battery state-of-charge remaining after a safe hover landing.

Then to claim the world’s first two-pilot electric helicopter flight, the battery capacity was reduced by 18 percent to allow Rothblatt to fly with Webb.

On Dec. 7, 2018, Tier 1 Engineering set a Guinness World Record when Webb flew the farthest distance traveled by an electric helicopter, covering 30.7 nautical miles (56.87 kilometers) at an average speed of 80 knots (148 km/h) over a circular course entirely within the confines of the Los Alamitos military base.

Original Story: https://verticalmag.com/news/tier-1-engineerings-electric-e-r44-makes-historic-airport-to-airport-cross-country-flight

Vertical Magazine By Ken Swartz - November 2, 2022 | Photo by Dan Megna Photography

After the record flights, Tier 1 set out to optimize the e-R44 design and replace the automotive systems with hardware that could be certified for aviation.

The first improvement was cutting the weight of the battery pack from 1,100 lb. (500 kg) to 800 lb. (365 kg) by early 2020. This was achieved by using higher energy-density cells and a streamlined structure to support them. It meant the e-R44 could fly with a pilot, co-pilot and organ transfer system.

When the second electric motor and invertor did not perform as expected during ground tests, Tier 1 transferred the YASA motor and Rinehart Motion Systems inverters to the second-generation e-R44.

The second iteration of the design included four independent onboard liquid cooling systems in the engine bay for the motors (packaged as a single unit), the inverters, reduction gearbox and battery pack.

In the cockpit, the twist grip throttle on the collective was removed and rotor RPM is now fully controlled by the electric motor controller. "There is no need for pilot input into the throttle," said Dromgoole in an earlier interview with the author during the Vertical Flight Society’s 9th Annual eVTOL Symposium in San Jose in January 2022.

The toggle switch on the end of the right seat collective used to switch the RPM governor on and off is now used to select 100 percent RPM for normal operations, or 90 percent RPM to allow autorotation training. That allows the pilot during a practice autorotation to adjust the rotor speed using the cyclic and collective, and "if the rotor RPM was to drop to 90 percent or less, the motor will automatically pick up and apply torque, which is an added safety feature," Dromgoole explained.

Original Story: https://verticalmag.com/news/tier-1-engineerings-electric-e-r44-makes-historic-airport-to-airport-cross-country-flight

Vertical Magazine By Ken Swartz - November 2, 2022 | Photo by Dan Megna Photography

In December 2021, the e-R44 program gained renewed momentum when Tier 1 Engineering selected the magniX magni350 electric motor.

"magniX was chosen as they are leading the industry in the development of aviation-specific electric propulsion, and we recognized that significant progress had been made towards obtaining FAA certification," said Dromgoole when the motor deal was announced. "With magniX’s technology, we are now much closer to obtaining a supplemental type certificate [STC] approval of the e-R44 and transforming the delivery of life-saving human organs,"

Tier 1 took delivery of a prototype magni250 on Dec. 6, 2022, to integrate into its third-generation e-R44, which will be the basis for its FAA STC application. The airframe of the proof-of-concept e-R44 aircraft, N3115T, is being reused as a platform for the new electric motor.

The Magni250 is twice the diameter of the YASA motor, but is a better match to the speed and torque of the original Lycoming IO-540-AEA5 engine.

This has helped to simplify the rotor drive system on the third-generation e-R44 by replacing the engine reduction gearbox (required for the 5,600 RPM YASA motor) as well as the R44’s original vee-belt drive and automatic tensioner with a synchronous belt drive. The changes have simplified pilot workload and result in additional weight savings.

The initial ground runs of the third-generation e-R44 began on March 31, 2022, with Webb and Rothblatt performing system checks to validate the cooling system and engine controls of the magni250.

This was followed by first flight at Los Alamitos on June 4, which lasted three minutes, with Webb and Rothblatt again at the controls.

Original Story: https://verticalmag.com/news/tier-1-engineerings-electric-e-r44-makes-historic-airport-to-airport-cross-country-flight

Vertical Magazine By Ken Swartz - November 2, 2022 | Photo by Dan Megna Photography

Tier 1 Engineering has been planning a cross-country e-R44 flight for several years, but ground and air testing of the new propulsion system needed to mature before the FAA would grant the required flight permit.

Since the first flight, the helicopter had completed 16 test flights totaling approximately three hours, as well as extensive testing at full power with the e-R44 anchored to the ground through the summer.

It was brought by trailer to Thermal Airport in the week prior to the flight, along with a ground charging unit.

On the morning of the record setting flight, Webb and Rothblatt flew the approved route in a piston-engine Robinson R44 owned by Lung Biotechnology shortly before they took off in the e-R44.

Webb said one of the novelties of the flight was that the e-R44 electric engine doesn’t emit a lot of heat in flight or on landing.

There are still gaps in the FAA regulations when it comes to addressing electric aircraft, even if it is an STC conversion rather than a clean sheet design.

One challenge for any electric aircraft developer will be to demonstrate the "means of compliance" with the new regulations to validate the electric propulsion systems.

That’s why Tier 1 has been an active participant in industry committees interpreting airworthiness standards and developing consensus standards specifically for electric propulsion systems.

While the e-R44 offers a zero emissions means of performing traditional helicopter flights, Dromgoole believes that the business case for the aircraft will also include about a 20 percent reduction in noise (from the engine) and a 20 percent reduction in operating costs compared to a piston R44, as a result of maintenance savings and lower energy costs.

The exact cost saving will only be known once the cost and replacement life of the battery cells is known, and this has been changing over time.

Tier 1 also sees a market opportunity for the e-R44 in regions of the world where aviation gasoline is very expensive or unavailable. This includes nearby Catalina Island Airport, 34 miles (54 kilometers) offshore from Los Alamitos Army Airfield.

The company believes that the best time to convert an R44 to electric propulsion is during the factory mandated 2,200-hour or 12-year overhaul of the helicopter, which typically costs more than $230,000 and includes an engine exchange.

It plans to open e-R44 conversion line at its facility in Santa Ana to fill orders from Lung Biotechnology and Webb’s OC Helicopters, which was the first charter helicopter operator to place an order for the e-R44.

As Dromgoole left Palm Springs Airport after a momentous day, he paid tribute to Tier 1’s small team of multitalented employees

"I’m really proud of the team today. They’ve done a lot of work. It’s taken a lot of time to get to this point."

Original Story: https://verticalmag.com/news/tier-1-engineerings-electric-e-r44-makes-historic-airport-to-airport-cross-country-flight

Vertical Magazine By Ken Swartz - November 2, 2022 | Photo by Dan Megna Photography

Flight of Battery-Powered Robinson 44 Helicopter Accelerates Path to Sustainable Delivery of Life-Saving Organs

magniX, a manufacturer of electric propulsion solutions for aviation, is pleased to have powered the first fully-electric helicopter flight between airfields, in partnership with Tier 1 Engineering. The modified electric Robinson 44 (eR44) helicopter powered with a magniX magni250 electric propulsion unit (EPU) made its historic journey from Jacqueline Cochran Regional Airport to Palm Springs International Airport, arriving on 29 October 2022 at 11:00am PST, in a flight that lasted approximately 20 minutes.

Tier 1 Engineering is developing the magniX-powered eR44 for Lung Biotechnology PBC, a subsidiary of United Therapeutics Corporation, a biotechnology company dedicated to addressing the severe shortage of transplantable organs in the U.S. The magniX EPU was retrofitted into the helicopter together with a battery system developed by Tier 1 Engineering, specialists in the design and development of electric aircraft. The eR44 is designed to deliver human and manufactured organs for transplant with zero carbon emissions at the point of use.

"Building from our first flight of the eR44 helicopter last June, the successfully completed point-to-point flight takes us a step closer to the sustainable transport of life-saving organs," said Nuno Taborda, CEO of magniX. "magniX is excited to be part of an initiative that will positively affect those in need of urgent medical care. This is only the start of the applications for electric helicopters, which have a bright future as low-cost, carbon-free, reliable alternatives to combustion engine models."

magniX Celebrates Another Industry First

Since December 2019, magniX has also provided the technology to power a number of first flights, including that of Harbour Air’s "eBeaver", a Cessna "eCaravan" and, most recently in September 2022, Eviation’s all-electric commuter aircraft, Alice. This point-to-point flight of an electric rotary aircraft represents the latest first for the industry-leading electric solutions company. Tier 1 Engineering is currently working with the FAA on the eR44 project to obtain a Supplemental Type Certificate (STC). Lung Biotechnology PBC plans to acquire a fleet of sustainable aircraft to transport transplant organs.

"We are committed to charting a new path forward for the zero-carbon delivery of life-saving organs," said Dr. Martine Rothblatt, one of the helicopter’s pilots and CEO of United Therapeutics Corporation. "Saturday’s point-to-point flight proves that the technology necessary for our mission is already here, as we actively work with the FAA to certify the eR44 helicopter."

"Together we achieved an incredible outcome for the world’s first airport-to-airport cross-country all-electric helicopter flight," said Glen Dromgoole, President of Tier 1 Engineering. "magniX has again demonstrated the reliability and power of its electric propulsion units, and we’re proud to continue this journey to create sustainable options for organ donation and, ultimately, help save lives."

Original Story: https://www.prnewswire.com/news-releases/magnix-powers-first-point-to-point-flight-of-an-all-electric-helicopter-301668925.html

PR Newswire by Everett, Wash. - November 4, 2022 | Photo by Dan Megna Photography