Dufour Set To Ship Aero2 Drones to Customers for Real-world Feedback
Swiss company has completed an initial round of test flights with the hybrid-electric tiltwing
Dufour Aerospace has completed the first phase of test flights with its Aero2 hybrid-electric VTOL aircraft.

Dufour Aerospace said the recent completion of initial flight testing for its Aero2 multi-role drone has proven the viability of the aircraft’s hybrid-electric powertrain and tiltwing architecture. In a program update this week, the Swiss company reported that it is preparing to deliver a limited number of pre-series examples of the Aero2 to prospective customers as part of its efforts to gather more data from “real-life” operations.

Dufour said it now intends to extend the duration of test flights, while also intensifying preparations to start commercial production around the middle of 2026. Customers’ pilots, flying under EASA’s experimental rules, will have the opportunity to fly the Aero2 in various locations and provide the manufacturer with technical feedback. Among previously reported early adopters of the Aero2 is Swedish operator European Medical Drone.

The recent series of 10-minute flights, which began in August 2024, was conducted with the Aero2 prototype ballasted to simulate a typical maximum takeoff weight. Projected useful load of the uncrewed aircraft is 52 kilograms (about 115 pounds), consisting of a 40-kilogram payload and 12 kilograms of fuel for the turbogenerator. It is expected to have a range of up to around 400 kilometers (216 nm) at a speed of 92 knots.

Batteries Recharge In-flight

During takeoff, the Aero2 is powered entirely by its batteries, which reduces noise levels close to the ground. As the aircraft transitions from vertical to forward flight, the Suter Industries TOA228 engine kicks in to generate electricity to power the electric motors and recharge the batteries. Currently, the engine uses conventional gasoline, but Dufour aims for it to be able to use sustainable aviation fuels.

Dufour’s team has developed the Aero2’s flight control system and software, power management system, and integrated powertrain in-house. Deliveries of time-critical loads, such as medical supplies and industrial spare parts, are envisioned as being among the early use cases, as well as remote-sensing missions.

“The beauty of the Aero2 is mission efficiency and a simpler system for charging aircraft,” said Dufour Aerospace CEO Sascha Hardegger. “Our customers do not need to plug in the Aero2 for hours to run their next mission. Recharging is accomplished in the air, not on the ground, enabling back-to-back missions. It can land, exchange the payload, and restart the mission immediately.”

Dufour, which is based near Zurich, has longer-term plans to develop a larger hybrid-electric VTOL aircraft called the Aero3. The plan is that this could be used for passenger transportation with up to eight seats, or to carry payloads of up to 750 kilograms on flights of up to around 554 nm.