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Collins Advances Testing of 1MW Electric Motors for Hybrid Systems

Collins Advances Testing of 1MW Electric Motors for Hybrid Systems
Collins Aerospace has commenced testing of integrated electric components, including two 1MW-class motors, as part of efforts to hybridize the Pratt & Whitney PW1100G engine under the European Union’s Clean Aviation-supported SWITCH project. These trials are being conducted at Collins’ electric power systems laboratory in Rockford, Illinois, known as “The Grid.” The primary goal is to validate the performance of electric motor-generators, controllers, and power distribution systems before their installation on the PW1100G engine for subsequent ground testing. The MTU Aero Engines-led initiative is expected to reach completion later this year.
Objectives and Technical Development
The SWITCH project aims to demonstrate the viability of hybridizing a narrowbody engine, specifically the Pratt & Whitney geared turbofan (GTF). By integrating electric motors on both the high- and low-pressure spools, the hybrid system is designed to supplement the gas turbine during critical phases such as take-off and climb. This approach allows the thermal engine to be optimized for cruise conditions, thereby enhancing overall efficiency across various flight stages.
Collins Aerospace developed and manufactured the motors and controllers at its Solihull facility in the United Kingdom, while power distribution components were engineered in Nordlingen, Germany. GKN Aerospace contributed by producing the high-voltage electrical wiring interconnection system in Papendrecht, the Netherlands. The SWITCH engine targets a 20% reduction in fuel consumption, with plans to incorporate a waste-heat recovery system to further improve efficiency.
Challenges and Industry Implications
The advancement of hybrid-electric propulsion at this scale presents considerable technical challenges. Collins must ensure the hybrid system’s reliability and efficiency, achieve seamless integration with existing PW1100G engines, and comply with stringent regulatory and performance standards. These hurdles are critical as the aviation industry seeks more sustainable propulsion solutions.
Market interest in hybrid-electric propulsion is intensifying, with airlines closely monitoring developments that promise reduced emissions and lower operating costs. Collins’ progress is expected to heighten competition, encouraging rivals such as Ascendance Flight Technologies and Archer Aviation to accelerate their own hybrid-electric initiatives. These competitors may also pursue additional funding and partnerships to remain competitive in this evolving sector.
Future Prospects and Funding
By the end of 2024, the SWITCH project aims to reach technology readiness level (TRL) 5 for the hybridized engine through extensive ground testing. The waste-heat recovery system is anticipated to achieve TRL 4 following validation of its core technologies, according to Clean Aviation project documentation.
Clean Aviation has allocated €60 million ($70.3 million) in its latest funding round to support ground demonstrators for up to three hybrid-electric narrowbody engines. Selected projects will be announced in the autumn, with activities scheduled to commence in January 2027. It remains unclear whether this funding will extend to flight testing, although the Airbus-led COMPANION project, developed during Clean Aviation’s first phase, is working toward integrating a hybridized engine on its A380 testbed.
As Collins advances its testing program, the outcomes will be closely observed by industry stakeholders, regulators, and competitors, marking a significant milestone in the pursuit of hybrid-electric propulsion for commercial aviation.

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