How Archer Aviation is Redefining Electric Aircraft Design

Electric vertical takeoff and landing (EVTOL) aircraft are no longer the stuff of science fiction. Today, thanks to companies like Archer Aviation, the vision of low-noise, efficient air travel over congested cities is rapidly approaching reality. Recently, Munro & Associates visited Archer’s facility for a deep-dive look at their electric aircraft—specifically the Midnight, an EVTOL platform that combines the vertical lift capabilities of helicopters with the speed and efficiency of airplanes. During the visit, the tour unveiled key details about Archer Aviation’s aircraft design, propulsion systems, and modular battery architecture.

From Automotive Roots to Aviation Heights

Archer CTO Tom Muniz emphasizes how, in particular, automotive EV breakthroughs are accelerating aerospace innovation. The Midnight aircraft is a direct beneficiary of battery, motor, and systems engineering honed in the electric vehicle sector. By drawing on established supplier networks, proven design strategies, and automated manufacturing techniques from automotive practices, Archer is avoiding many of the common pitfalls that typically delay aerospace ventures.

For example, rather than outsourcing testing equipment, Archer built its own motor dynos in-house—cutting costs dramatically and speeding up iteration cycles. This vertical integration approach echoes early Ford methodology and embodies lean manufacturing principles: control your tools, master your data, and build everything with purpose.

Motor Innovation with Aerospace Precision

Archer’s electric propulsion system centers on a self-contained power unit that includes:

• An integrated inverter
• Planetary gear reduction
• Lightweight aluminum forging
• Custom electromagnetic design

Each Midnight aircraft uses 12 of these motors, each driving a dedicated propeller. Importantly, this redundancy isn’t just a feature—it’s a necessity. When it comes to aviation, every gram saved matters, and to that end, the team has meticulously optimized every component, ranging from rotor hub thicknesses to torque profiles.

The custom-built dynos also simulate real flight conditions. Entire motor testbeds tilt and rotate to replicate in-air maneuvers, allowing engineers to monitor oil flow, heat exchanger performance, and mechanical endurance. This enables Archer to gather extensive real-time performance data—essential for flight certification and safety validation.

Battery Architecture: Redundant, Modular, Robust

Perhaps the most impressive element is Archer’s battery pilot line. Each Midnight aircraft features six 24.5 kWh battery packs, mounted in pairs under each wing. These use 2170-format cells in a 210S7P configuration and offer complete redundancy—any single pack or motor can fail without compromising flight safety.

Archer’s pilot line automates where quality and data traceability demand it, but not yet for cost efficiency. Key steps include:

• Optical inspection using multiple cameras
• Electrical testing (open-circuit voltage, AC IR resistance, temperature)
• Cylindricity checks for tight-fit foam holders
• Adhesive dispensing for consistent bond-line thickness
• Laser cleaning and welding across 450 points per pack

In total, over 10,000 data points are collected per pack. The line currently supports 1,000 packs/year but is designed to scale to 15,000 with minor de-bottlenecking. That’s enough for over 650 aircraft annually, already baked into current investments.

Scaling Production: From 650 to Thousands

The first phase of Archer’s Georgia factory will deliver 650 aircraft/year, with expansion plans reaching 2,000+ units annually. But higher volumes demand structural innovation—particularly in carbon composite fabrication.

While current aircraft use pre-preg carbon fiber, scaling to tens of thousands of parts will likely require:

• SMC (Sheet Molded Compound) for fast, one-stroke body panel forming
• AFP (Automated Fiber Placement) for high-strength load-bearing components like wing spars
• Snap-cure resins to reduce cure cycles from hours to minutes

Munro suggests Archer look to lessons learned in automotive composite production—like BMW’s i3 or Aptera’s streamlined SMC approach—as blueprints for mass-scale efficiency.

Simulation and Validation: Hardware-in-the-Loop

Archer’s Iron Bird lab replicates the full aircraft system architecture in a ground testbed. Real avionics, wiring harnesses, battery packs, and motor controllers are linked to simulation systems that allow engineers to inject failures and observe system responses.

The simulator isn’t just software—it’s hardware-in-the-loop testing at its finest. This method ensures that what works in theory also works under real-world electrical loads, failure modes, and operator input. A simplified cockpit interface offers intuitive flight control, signaling the aircraft’s user-friendly future.

In test mode, for example, pulling back on the stick lifts the aircraft; moving the thumb-switch triggers transition to fixed-wing flight. By comparison, it’s a far cry from traditional pilot-heavy systems, reflecting Archer’s vision of simplified, accessible urban air mobility.

Archer Aviation Aircraft Design Takeaways

• Weight Optimization is King: Aircraft engineering demands aggressive weight savings. Forged aluminum, thin casings, and minimal material tolerances reflect aerospace rigor.
• Redundancy Drives Safety: With six battery packs and 12 independent motors, Archer’s design mitigates failure at every level. This is a core tenet of aviation-grade reliability.
• Smart Automation, Not Blind Automation: Archer only automates where it boosts product quality or data fidelity. High-efficiency automation for cost will follow once foundational quality is proven.
• In-House Mastery Matters: From dynos to battery pilot lines, Archer’s investment in internal capabilities echoes Munro’s mantra: outsource intelligence, and you lose it.
• Composite Manufacturing Is the Next Bottleneck: Scaling EVTOLs to tens of thousands per year will hinge on breakthroughs in structural part production, particularly carbon fiber.

Final Thoughts: Flying Forward

Archer Aviation is doing more than just prototyping a futuristic idea. They’re building a vertically integrated, technically mature EVTOL platform rooted in real-world manufacturing insight. From motor design to battery validation to full-system simulation, their approach feels less like a startup and more like a next-generation aerospace company.

At Munro & Associates, we believe Archer is on the cusp of redefining regional mobility. Their success will depend not just on engineering innovation but on their ability to scale, adapt, and learn from the best practices of both automotive and aerospace sectors.

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