Saft AirLion™ lithium-ion aviation battery passes thermal runaway safety testing with flying colors
The AirLion™ battery has successfully passed the thermal runaway containment test, which is crucial for obtaining DO-311A certification
Test confirms the safety of the rechargeable 28 V Li-ion battery for onboard backup and powerful engine starting for aircraft programs
Replacing a lead-acid battery with AirLion™ could reduce the total weight of an aircraft by 20 to 30 kilograms (kg)
October 15, 2025, Las Vegas (US) – Saft, a subsidiary of TotalEnergies, has successfully completed stringent DO-311A full thermal runaway battery containment testing for its AirLion™, lithium-ion (Li-ion) aviation battery. This is an important step towards the commercial application of this game-changing 28-volt (V) battery for onboard backup and engine starting applications.
DO-311A is administered by the Radio Technical Commission for Aeronautics (RTCA) and adopted by the Federal Aviation Administration (FAA) and the European Union Aviation Safety Agency (EASA) for certification of lithium batteries for use in aircraft. It is the highest standard for lithium-ion aviation batteries in terms of performance, design and safety.
“Aviation authorities, such as the FAA and EASA, require lithium batteries to have robust safety features, including venting mechanisms, to be certified for airborne use. Our teams at Saft have been working hard to develop an efficient, reliable, and safe lithium-ion battery. Passing this test is crucial for bringing the AirLion to market”, said John Sarazen, Marketing Manager with Saft’s Aerospace, Defense & Performance (ADP) division. “We introduced the AirLion battery less than a year ago. The fast-track completion of the thermal runaway testing is a testament to the capabilities of our dedicated in-house engineering teams and the excellent design of the battery system.”
Saft introduced the AirLion battery at NBAA-BACE 2024 (National Business Aviation Association-Business Aviation Convention & Exhibition). It is designed to store over twice the energy in the same weight and one and a half times the energy in the same volume as a traditional lead acid battery. By switching to a Li-ion battery, the total weight of a single aircraft could be reduced by 20 to 30 kg with a positive impact on fuel consumption and CO₂ emissions.
The AirLion is adapted from Saft’s Xcelion battery product range. This is a maintenance-free solution based on Saft’s own proprietary cell chemistry, with over 20,000 units in current operation in some of the harshest environments. Each battery contains integrated smart capabilities to provide real-time battery health and status information. In addition, the battery features an aerospace-grade Military – Specification interface.
Because Saft is one of the few battery companies to own the entire process from design, electrochemistry, cell production and manufacturing, it can ensure the highest level of safety and performance of its products. The AirLion was developed at Saft’s R&D facilities in Cockeysville, USA and Bordeaux, France, while it is being manufactured and qualified at Saft’s factory in Valdosta, USA, an existing aviation-certified facility.
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About Saft
Saft specializes in advanced technology battery solutions for industry, from the design and development to the production, customization and service provision. For more than 100 years, Saft's longer-lasting batteries and systems have provided critical safety applications, back-up power and propulsion for our customers. Our innovative, safe and reliable technology delivers high performance on land, at sea, in the air and in space.
Saft is powering industry and smarter cities, while providing critical back-up functionality in remote and harsh environments from the Arctic Circle to the Sahara Desert. Saft is a wholly owned subsidiary of TotalEnergies, a broad energy company that produces and markets energies on a global scale: oil and biofuels, natural gas and green gases, renewables and electricity.
We energize the world. www.saft.com
Press Contacts
Saft
Belén d’Alexis, External Communications Manager
Tel.: +33 1 58 63 16 60, email: belen.dalexis@saft.com
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