Why the FAA’s eventual certification of ZeroAvia’s 600kW Electric Propulsion System will Electrify AAM

On August 19th, 2025, the FAA granted a P-1 Special Conditions Issue Paper for ZeroAvia’s 600kW Electric Propulsion System (EPS). This regulatory milestone comes after the FAA G-1 in February 2025.

From the FAA:

Certification Basis (G-1). G-1 is an IP that designates the applicable airworthiness and
environmental regulations (i.e., noise, fuel venting and exhaust emissions), including ELOS
findings and special conditions that must be met for certification as stated in 14 CFR 21.17, 21.21,
21.25, 21.27, 21.29, or 21.101, as applicable. It also designates the applicable Special Federal
Aviation Regulations (SFAR) and records any exemptions granted (see 14 CFR 11.15 and 11.81).
This IP must provide the definitive justification for selecting the certification basis, including
specific amendment levels.

 The P-1 Issue Paper describes the criteria and circumstances required for ZeroAvia’s novel and brilliant 600 kW electric propulsion system (EPS) to become certified by the FAA. These criteria, set forth within the FAA’s Special Conditions rule, will be made public in the Federal Register. The next phase pertains to the methods for achieving FAA compliance of this novel design.

Per the FAA:

Ҥ 11.19 What is a special condition?

A special condition is a regulation that applies to a particular aircraft design. The FAA issues special conditions when we find that the airworthiness regulations for an aircraft, aircraft engine, or propeller design do not contain adequate or appropriate safety standards, because of a novel or unusual design“

The outcome of the FAA certifying ZeroAvia’s 600kW Electric Propulsion System (EPS) will be tremendous:

“Getting this electric propulsion system certified and into service will be a monumental leap in the next great transition in aviation: from fossil fuel combustion to electric aviation. Electrifying aviation will deliver a step change in efficiency plus steep reductions in operating costs by overcoming volatile fuel prices and the costly maintenance of complex, high intensity combustion engines.”– Val Miftakhov, Founder & CEO,  ZeroAvia

ZeroAvia’s 600 kW electric propulsion system can be utilized in aircraft that carry small groups of passengers, and works well for applications such as eVTOLs, CTOLs, and STOLs that seat anywhere from 4 to 6 passengers (plus pilot).

Why Electric?

Electric eVTOLs are currently the predominant mode of propulsion offered by the major eVTOL, CTOL and STOL OEMs that will build air taxis for transporting people from the suburbs to the cities, or across different landmarks of big cities. While ZeroAvia can configure such electric motors for a hybrid electric or hydrogen fuel cell propulsion system, ZeroAvia still wants to make its presence known in the market for all-electric aircraft platforms (such as eVTOLs, STOLs and CTOLs). The flexibility in end-use provided by ZeroAvia’s electric motors and inverters, will help ZeroAvia in multiple ways. First, the tremendous resources required in both capital and R&D hours that were funneled into electric motors and related components will be useful and readily applied across the board to ZeroAvia’s hybrid-electric and hydrogen-electric propulsion systems. The massive market for electric-propulsion systems in all-electric eVTOLs can provide ZeroAvia the profit, and therefore funds to invest more into further hybrid-electric, and hydrogen-electric propulsion technology.

“While hydrogen-electric is the future for the majority of commercial routes in existence today, advances in electric propulsion technology and novel aircraft design are opening up an exciting range of new shorter range, electric air mobility applications. Certifying and selling our 600kW electric propulsion system helps ZeroAvia expand our addressable market and increase our impact in pursuit of a clean future of flight.”– Val Miftakhov, Founder & CEO,  ZeroAvia

OEMs such as Horizon Aircraft, which has recently announced the intent to collaborate with ZeroAvia on a future hydrogen-electric version of Horizon’s exceptional multi-role 6 passenger +1 pilot Cavorite X7 hybrid-electric eVTOL, will stand to gain with each step ZeroAvia comes closer to producing its ZA600 hydrogen-propulsion system. ( For more info read our article here: Fueling the Future: Why Horizon Aircraft’s multi-role Cavorite X7 eVTOL will be a game-changer in the green AAM industry: click here )

660 kW 4×3 Phase Permanent Magnet Synchronous Machine 650–820 Vdc

ZeroAvia’s first electric motor is a high-efficiency, 660kW surface permanent magnet machine, purpose-built for direct-drive applications mounted directly to the propeller. Engineered to aerospace standards, the motor incorporates advanced stator and rotor technologies to achieve exceptional power density and reduced weight. Its optimized direct cooling system—using standard turbine oil—ensures efficient thermal management, allowing the motor to operate at lower temperatures for extended periods. Integrated thermal sensors monitor coil temperatures for added safety and performance. The stator core is segmented into four sections, improving fault tolerance and enabling higher current input from the inverters.

600 kW Electric Motor

• 660 kW max power
• Max speed: 1,900 rpm
• 1,900 rpm
• Max Speed
• Power Density 4.5 kW/kg
• Stator core
• divided in 4
• Permanent magnet, radial flux electric
• motor
• High Torque: 3,250 Nm
• Efficiency: 94-96% vs load and speed
• Weight: 148 kg

225 kW Inverter 400–820 Vdc

ZeroAvia’s inverter is a high-efficiency system based on Silicon Carbide (SiC) technology, purpose-built for operation at high altitudes and in unpressurized environments. It converts high-voltage DC (HVDC) into three-phase (3Ф) AC power and is engineered from the ground up to meet aerospace requirements. The design emphasizes high segregation and fault tolerance, while delivering high power density and reduced weight through advanced thermal management and system integration. This ensures reliable, high-performance operation and efficient use of space, making it well-suited for placement within the engine compartment.

Four 200 Watt Silicon-carbide Inverters

• 225 kW max power
• HVDC to 3-phase AC
• Power Density 20 kW/kg
• DC Source Agnostic
• The system architecture is designed with a 4-way redundancy of the inverters, allowing
• full power operation in result of single inverter failure.
• The redundancy enables safe motor control on reduced power operation and does not
• impact receiving critical engine data.
• Fault Tolerance
• DC
• AC/AC/AC
• HVDC 400-830 Vdc, LVDC 18-35 Vdc
• Switching Frequency: 20 kHz
• Shock and vibration isolation
• Digitally controlled torque, speed and
• DC power
• Weight 10 kg

Propulsion Center of Excellence 🇺🇸

ZeroAvia built a new Propulsion Center of Excellence at Paine Field in Everett, Washington state (north of Seattle) where electric powertrains (including hybrid-electric, and the ZA600 hydrogen-electric) will be designed and manufactured for use in a variety of aircraft.

Hydrogen Power

Undoubtedly, the technology that went into many of the components for ZeroAvia’s 600kW Electric Propulsion System (EPS) will be harnessed for its ZA600 power generation system (PGS), and even larger hydrogen systems.

ZA600 power generation system (PGS)

• Max Continuous Power: 200 kWe
  •Operating Voltage: 910 V – 570 VDC
  •Operating Current: 0 A – 300 A
  •Gravimetric Power density: 1.4 kW/kg
• Volumetric Power density: 0.78 kW/L
• 55 – 60 % overall system efficiency
• Maintenance overhaul frequency +10,000
• Continuous Power output under ±6 G shocks in all directions
• Power output under transient -1.52 G
• Safe under 18 G crash loads forward
• Safe under 13.5 G crash loads down
• Continuous Power during 60° Roll, Pitch and Yaw
• Single channel is 2×455 Fuel Cell Stack

Hydrogen Airport Refueling Ecosystem (HARE)

Getting to our destination: whether by all-electric, hybrid-electric, or hydrogen-electric

With a broad range of propulsion systems ZeroAvia is offering to the market (and OEMs), ZeroAvia can reap success across the various platforms of future aviation, whether it be eVTOLs, STOLs, and CTOLs; piloted and unpiloted; drones or passenger aircraft. ZeroAvia will have you covered!

Air travel has been bringing the world together for more than a century, but we can do better for passengers trying to get to and from underserved communities, hours away from a hub airport. ZeroAvia and others in advanced air mobility are laying the groundwork to connect more people, more affordably, and to more places.”  – Val Miftakhov, Founder & CEO,  ZeroAvia

✈️  Stay tuned to eVTOL buzz for test flight updates, tech deep dives, and exclusive interviews as this story evolves.

More Info:

ZeroAvia’s official press release: click here

Fueling the Future: Why Horizon Aircraft’s multi-role Cavorite X7 eVTOL will be a game-changer in the green AAM industry: click here

FAA Issue Paper process: click here

FAA Special Condition: click here

ZeroAvia Receives FAA G-1 for 600kW Electric Propulsion System: click here