Fafali Aircraft are powerplant and energy source agnostic. This means that the airframe itself has been redesigned from the ground up to be ready to move towards net zero from the get-go. Every airframe we produce is 'upgrade ready' for alternative powerplants and energy storage solutions. Every one of our structures is conceived with tomorrow in mind.
The year 2050 is the target for nett zero aviation. That is less than 7,000 working days away BUT to meet this target, we believe that industry needs to be working on and implementing solutions today.
Here at Fafali we are working towards our first low-emissions, fuel flexible airframe ready to fly in 2024, with our hybrid version flying in 2025, and our first fully net-zero solution operational soon after.
We have a clear path to large scale production of 2-, 3- and 4-seat nett-zero aircraft before 2030. But it is not only the emissions in operation that we are concerned with. We are changing the carbon footprint of light aviation through design and production from the outset.
The grade of Aluminium we use is long lasting (we expect our airframes to have a life of up to 50 years (or more) when properly maintained, and is highly recyclable, using only 5% of the original energy input to recycle. Working with this grade of material, and our production methods ensure a non-toxic production of parts - both for our staff and the environment - and ready recyclability of waste materials that result from production.
We produce over 95% of the components for Fafali in house, bringing mainly raw materials in for production, and moving straight from our state-of-the-art 4 and 5 axis low energy consumption production cell to assembly within just a few metres. This reduces mass and volume from the transport industry, reduces packaging and therefore the energy of packaging production, packaging carbon and disposal of packaging carbon also. We estimate that we reduce packaging and transport carbon by over 80%.
We use the waste heat from production to heat our production cell and also our offices reducing our energy demands. Furthermore, our production cell has a 'winter' and 'summer' insulation configuration to ensure that the same heat we use in winter is not a burden in summer. We can change over between our configurations in a matter of hours.
Our production methods improve working conditions also. An average aluminium non-part-21 aircraft currently arrives in the UK in kit form, with a large amount of paperwork (total paper reduction per aircraft is 100s of pages). This results in tens of hours of unpacking, inventory, labelling and storing of parts. Not only do we reduce the labour content and packaging but also all the shipping and packing documentation. Over a year of production we can improve working conditions for our staff, packaging, paper-work and printing, and we eliminate the use of solvents used to remove parts identification labels.
Furthermore, the packaging that inevitably comes with our raw-materials is reused in over 98% of cases.
Our innovations are not just related to production but for maintenance, replacement, upgrade or recycling, our design is such that the
Fafali Aircraft are easily maintained and repaired, ensuring a long service life with outstanding awareness of the environment in production, operation and at the end of life.
Fafali Aircraft aim to be the leading light aircraft solution not only in our operational missions but also in regards to environmental awareness from materials selection, production, operations, upgradeability, and end-of-life recyclability.