As the advanced air mobility sector prepares for commercial operations, traditional propeller manufacturer Hartzell Propeller is making substantial investments to scale its production and engineering capabilities.
The company officially opened its new Innovation Center at the Piqua, Ohio headquarters in February 2026. The project adds more than 150,000 square feet of space dedicated to carbon fiber blade manufacturing, WhirlWind experimental propeller lines, research and development, and a service center. Supported by a $2 million grant from JobsOhio, the expansion is part of a broader commitment exceeding $40 million that more than quadruples Hartzell's previous carbon composite production area.
President JJ Frigge indicated the upgraded facility provides capacity for over 15,000 blades per year, a significant jump from the current output of around 5,000. Company officials expect the new capacity to be utilized rapidly as AAM platforms move closer to certification and entry into service.
A key driver is Hartzell's certified propeller program for Beta Technologies. In July 2025, the FAA granted Part 35 type certification for a custom five-blade, carbon-fiber pusher propeller specifically engineered for the Alia CX300 electric conventional takeoff and landing aircraft as well as the Alia VTOL model. The propeller has undergone extensive testing on Beta's proprietary electric propulsion systems, including long-distance flights. Beta aims to bring the Alia into commercial service in the coming years, while European validation of the Hartzell component continues.
Hartzell is applying similar expertise to additional AAM platforms. The firm is supplying propellers for French company Aura Aero's Integral R regional aircraft project and is engaged with several undisclosed vertical takeoff and landing developers. To support these specialized applications, the company has expanded its engineering team to conduct deep, mission-specific propeller design work.
Beyond new manufacturing, Hartzell has strengthened its global support network. In the past three years it has acquired nine propeller overhaul and repair shops in the United States, Canada and United Kingdom, including the recent addition of Brinkley Propeller Services, now operating as part of the Hartzell Global Services brand. The company plans further European expansion, likely through additional acquisitions, to locate repair capabilities closer to operators.
Frigge has emphasized that the aftermarket business is on track to generate $100 million in revenue during 2026. The combined strategy of production scale-up, targeted AAM partnerships and enhanced service infrastructure reflects Hartzell's confidence in the long-term potential of electric, hybrid and alternative propulsion aircraft.
Industry observers note that while AAM timelines have shifted in recent years, manufacturers like Hartzell that secure early certifications and invest in dedicated production are well positioned to capture market share as the segment matures. The Piqua expansion not only increases volume but integrates advanced manufacturing processes intended to maintain the quality standards the company has upheld for nearly a century.
With electric air taxis and regional electric aircraft expected to require large numbers of optimized propellers, Hartzell's moves illustrate how legacy general aviation suppliers are adapting to support the next generation of sustainable flight.