Samson Sky optimizes Switchblade Flying Car production process

Samson Sky, the company behind the Switchblade Flying Car, has announced a major upgrade to its manufacturing process that significantly cuts both production time and costs for key flying vehicle components.

The update is focused on a newly implemented system for producing carbon fiber parts. According to Samson Sky, this new process reduces production costs by 50% and increases part fabrication speed by 800% compared to traditional carbon fiber manufacturing methods.

“This allows us to scale faster and keep pricing competitive. […] We’ve integrated this process directly into how we prepare each vehicle,” Michael Maxwell, Samson Sky Chief of Research and Development, explained in the statement.

The new manufacturing system is part of Samson’s enhanced Builder Assist Program, which is designed to help customers comply with FAA rules requiring them to complete at least 51% of the construction for Experimental Category aircraft.

The manufacturer states that, instead of relying on manual labor or specialized skills, customers will use computer-guided machinery to produce their portion of the two-seat flying sports car. Automation will ensure precise part fabrication while significantly reducing manual effort. After the customer completes their share of the build, Samson’s technicians will handle the final assembly and perform thorough quality inspections.

The updated manufacturing system has reduced the time customers will need to spend at Samson’s Build Center from over three weeks to just one. The new carbon fiber production method is also more environmentally efficient, producing fewer emissions and generating less waste than conventional approaches.

Switchblade: a two-seat hybrid eVTOL for road and air

The Switchblade, an eVTOL, is a three-wheel, street-legal flying sports car designed for both road and air travel. This two-seat, hybrid-electric vehicle can be parked in a standard garage and driven to a nearby airport using local roads or highways. In under three minutes, its wings extend and its tail deploys, transforming it into a registered aircraft ready for flight.

With a cruising speed of 160 mph and a range of up to 450 miles on a single tank of premium auto fuel, the Switchblade allows travelers to fly to their destination and then switch back to driving mode for the final leg. Its compact design includes space for two passengers and luggage.

RELATED

Samson Sky secures 115 Switchblade flying car orders worth $22 million

Samson Sky currently has over 2,400 reservation holders across more than 50 countries. The company plans to begin customer deliveries in 2026.The post Samson Sky optimizes Switchblade Flying Car production process appeared first on AeroTime.

Go to Source