FlightSabers | Power Systems for Electric Aviation

Mission

Electric flight is limited by the battery. We build everything around it.

The next generation of aviation cells has the energy density to fly real routes. What does not exist yet is the system layer: the thermal control that keeps them in their operating window, the management electronics that know their state, the distribution hardware that moves their power, and the ground infrastructure that charges them in a turnaround window. FlightSabers builds that layer.

Products

One integrated power ecosystem, built from the cell outward.

In development

Thermal Management System

TMS

Aviation-grade active thermal control engineered for solid-state lithium-sulfur cells. Keeps every cell in its operating window through takeoff power and fast charge, within aviation mass budgets.

Bidirectional control: active heating and liquid cooling
State-of-charge aware cooling scheduled to where heat actually appears
Liquid-cooled cold plate as the primary architecture

In development

Battery Management System

BMS

Physics-based battery management built for lithium-sulfur chemistry, not adapted from lithium-ion. Accurate state estimation across the two-plateau discharge profile, with direct control of the thermal system.

Electrochemical models developed for Li-S behavior
State-of-charge and state-of-health estimation in flat voltage regions
Cell-level monitoring of voltage, temperature, and internal resistance

Planned

Power Distribution Unit

PDU

High-voltage DC distribution from pack to propulsion. Solid-state protection, redundant paths, and fault-tolerant architecture designed for aviation certification from the start.

Solid-state circuit protection and isolation
Redundant distribution paths for flight-critical loads
Integrated with BMS for pack-level fault handling

Planned

Ground Charging Infrastructure

2 MW Charging

Megawatt-class airport charging with intelligent power management. Battery energy storage buffers the grid while delivering 1.5 to 2 MW at the gate for commercial turnaround times.

1.5 to 2 MW delivery per aircraft stand
On-site storage to decouple charging from grid capacity
Thermal management extended to the charge cycle

Liquid-cooled aviation battery module concept

Technology foundation

Built on NASA SABERS solid-state lithium-sulfur cells.

FlightSabers is pursuing a NASA Research License for the SABERS technology portfolio, the most advanced aviation battery chemistry in development. We do not make cells. We build the systems that let these cells fly.

500+ Wh/kg energy density

Nearly double conventional lithium-ion. The threshold that makes regional and long-haul electric aviation viable.

No thermal runaway

A solid-state electrolyte replaces flammable liquid, eliminating the primary aviation battery safety concern and the fire suppression mass that comes with it.

Chemistry-specific systems

Lithium-sulfur has a different discharge profile and resistance behavior than lithium-ion. Our TMS and BMS are designed for it, not retuned from automotive systems.

Why the cell matters

The energy density gap, and the cell that closes it.

Today's lithium-ion cells top out around 250 to 300 Wh/kg, well short of what regional electric aviation needs once pack structure, cooling, and safety margins are added. SABERS cells cross that line at the cell level. The remaining work is the system around them.

Conventional Li-ion (NMC)250 Wh/kg

Silicon anode Li-ion450 Wh/kg

NASA SABERS solid-state Li-S500+ Wh/kg

Long-haul aviation requirement500 to 800 Wh/kg

NASA SABERS is at TRL 4 with successful coin cell and pouch cell demonstrations. FlightSabers is pursuing a Research License to build the management and power systems around it for aviation.

Megawatt aircraft charging infrastructure concept

Ground infrastructure

Megawatt charging at every gate.

Commercial electric aviation needs 1.5 to 2 megawatts per aircraft stand, delivered in a 30 to 40 minute turnaround. No airport is built for that today. Our ground charging roadmap pairs on-site energy storage with the same thermal control we build into the aircraft, so the charge cycle is managed end to end.

View the roadmap

Roadmap

From the cell outward.

We start at the battery because it is the highest-value, most technically defensible position in the stack. Each product builds on the one before it.

Now

Thermal and battery management

TMS and BMS for solid-state lithium-sulfur cells, developed together as one control system. Design, modeling, and bench validation are underway.

Integrated pack and distribution

TMS and BMS integrated into a qualifiable pack architecture, with the Power Distribution Unit carrying pack power to propulsion under aviation fault-tolerance requirements.

Then

Ground charging infrastructure

Megawatt-class gate charging with on-site storage and integrated thermal control, closing the loop between aircraft and airport.

Company

Built by engineers who understand safety-critical systems.

FlightSabers is an early-stage aerospace company in Austin, Texas. We combine aerospace engineering with hands-on experience in high-energy thermal and pressure systems, and we are building the team, partners, and capital to take these systems to flight.

We are working with

Research partners Technical advisors Early investors University partners Aircraft OEMs

Rudra Patel

Founder and CEO

Aerospace engineer with two years designing safety-critical high-pressure systems at ARC Automotive: pressure vessel design, DFMEA, hydro-burst testing, and production-level hardware development from concept through validation. BS Aerospace Engineering, University of Tennessee Knoxville.

Aerospace engineeringThermal systemsDFMEASolidWorksANSYSMATLAB

The battery systems that let electric aircraft fly real routes.