Making WAVES
November 2024
A frequently asked question I receive is, “What is taking so long?” Given the scale and complexity of a project like this, it’s worth explaining some of the key challenges we’ve faced and the strategies we’ve employed to address them.
The process of developing an aircraft like the WAVE has spanned nearly 15 years—approximately one-third of my life. To put this in context, one of our current employees was just five years old when this project began. The path to this stage has been characterized by sustained focus and incremental progress.
For the first three to four years, I was the only person dedicated full-time to the WAVE, working six to seven days a week on design and testing. These early years were focused on ensuring the structural and aerodynamic integrity of the aircraft—a process that was validated by its performance in initial tests, which showed excellent functionality directly off the drawing board.
It wasn’t until late 2016 that Vickers began scaling operations. This period marked our move to a larger facility and the start of assembling a dedicated team. Our early hires, though highly capable, were relatively new to the unique challenges of aircraft manufacturing. Building a skilled team that could effectively collaborate on this ambitious project was a gradual process, and assembling the right blend of talent and expertise took time. Today, the team has grown to approximately 20 members, who have collectively demonstrated an ability to deliver results that rival much larger organizations. Despite a modest budget and a streamlined team, we have successfully moved from design to production of a fully operational aircraft.
New Zealand’s regulatory environment presents an additional set of challenges for Light Sport Aircraft (LSA) manufacturing. Here, the Civil Aviation Authority (CAA)—similar to the U.S. Federal Aviation Administration (FAA)—requires LSA manufacturers to meet General Aviation (G.A.) manufacturing standards. Consequently, our company must adhere to rigorous standards and navigate various certification obstacles. The country’s stringent test pilot requirements, narrow the pool of qualified candidates for essential testing roles.
Our approach from the beginning has been to construct the prototype with production tooling, molds, and processes. This approach aims to reduce variability in future production stages, though it requires significant up-front investment in research and development (R&D). Creating production-ready tooling, molds, and composite structures is a complex process. Many manufacturers prioritize design at the expense of manufacturability, but we have chosen to focus on both, with an emphasis on building production efficiencies from the outset. This approach has necessitated extensive trial and error, as well as the development of detailed manufacturing protocols, especially given our use of composite materials.
Composite materials, particularly carbon fiber, pose additional complexity due to their variability. Unlike aluminium, for which structural properties and specifications are standardized and readily available, carbon fiber varies depending on the manufacturer. Each type of carbon fabric has unique characteristics based on the material’s weave, the machinery used in its production, and the proprietary resins applied by the supplier. When we receive the carbon fiber, further factors—such as the composition of the mold, oven types and curing cycles, and vacuum application techniques—affect the final product’s structural properties.
Each composite assembly undergoes rigorous testing. We produce hundreds of test samples (coupons) in various weights and configurations, which are sent to certified labs. These samples are then tested across a range of environmental conditions, including standard daily temperatures, elevated temperatures, hot and wet conditions, and extreme cold. This testing yields “material allowables” which guide the design and size of components to ensure compliance with our structural requirements. We repeat these tests with various adhesives to validate bonding integrity under similar environmental stresses.
This technical and regulatory rigor provides a snapshot of what’s involved in bringing a greenfield aircraft design to life. In addition to fundamental requirements, we have introduced unique features, such as automatic wing-folding, anti-flip landing gear, and water thrusters. Integrating these innovations on an amphibious aircraft, while staying within the weight constraints of the LSA category, adds another layer of engineering complexity. Yet, these features are critical to achieving the performance and usability targets we have set for the WAVE.
With all technical, regulatory, and design challenges considered, financing remains the ongoing priority. The process of securing capital to support long-term development is as complex as the technical aspects of the project. However, these efforts are essential to delivering an aircraft that will meet the high standards of safety, performance, and regulatory compliance in 2025, and this is why choosing the correct investors, that share our vision, is as critical as choosing the correct carbon fiber. Please share our ongoing investment search with your network, and help be part of bringing the WAVE to market.
NEWS UPDATE
Production Focus
Our team is firmly focused on moving into production as we enter the final stages of development. We’re excited to share some recent progress across key areas.
Water Thruster Testing
Our recent water tests of the WAVE’s water thrusters were a resounding success. The results showed excellent manoeuvrability, as well as impressive control and docking ease, underscoring the thrusters' efficiency and responsiveness. Please take a moment to view this brief video showcasing these capabilities:
VIDEO LINK | THRUSTER TESTING
Flight Testing
We are embarking on a new phase of flight testing to finalize the remaining design elements. This testing phase includes assessments of new propellers and production-ready anhedral tips for the horizontal stabilizer, all of which are designed to enhance stability, performance, and handling, while improving aesthetics.
Career Opportunities
As we accelerate toward full production, we are expanding our team. We are actively recruiting skilled professionals who are passionate about contributing to the aviation field. If you or someone you know has relevant experience, please consider joining our innovative team.
Open Positions:
- Composite Technicians – [Apply Here]
- Senior Stress/Structural Engineer – [Apply Here]
- Design/Production Engineer – [Apply Here]
- CNC Operator – [Apply Here]
Future Announcements
As part of our expansion strategy, we have some key updates scheduled for early 2025:
- Q1 2025: Initial U.S. sales and distribution location announcement
- Q2 2025: U.S.-based manufacturing State location selection
- Post-Production First Flight: Opening of order book and implementation of Customer Management System
Stay tuned for more updates as we progress toward production and beyond!