In this episode, we explore the detailed assembly of the HX50's main rotor system and learn how its design prioritises the needs of inexperienced pilots without compromising on safety, with an emphasis on high inertia for emergency manoeuvrability and low drag for efficient flight.

Dive deep into the complex world of gear production with our latest episode. Explore the intricate, multi-step process of manufacturing gears, highlighting the immense time and effort required to bring these essential components from concept to completion.

In the world of helicopter manufacturing, precision and efficiency are key to success. But which manufacturing process reigns supreme: casting or machining?

Dive into the world of the HX50 power electronics and discover how they efficiently convert, control, and condition electrical power for various systems. Get an exclusive look at the integrated Motor Generator Unit (MGU) and Power Management Unit (PMU), showcasing our commitment to vertical integration and cutting-edge technology.

In this episode, we take a look at the innovative methods that are being used to make the HX50's carbon fiber framework incredibly strong and resistant to vibrations. We discuss the challenges of creating a tailboom that is both strong and lightweight, and we show how honeycomb material is being used to achieve this.

Discover the intricate details that go into designing the doors of an HX50 helicopter. Learn how carbon fiber construction and design innovations contribute to a more luxurious and satisfying experience.

Get a glimpse of airframe number five and tailboom number one, showcasing the latest developments of the stunning HX50. With intentional design features, like the sacrificial piece under the tail fin, this nearly 10-meter long helicopter is changing the game in the general aviation market.

Join us as we as we unveil our latest acquisition - the Hexagon Leitz machine for ultra-precision measuring. In this video, we'll take you through the key features of this cutting-edge machine and why it's essential for measuring gears and other components with optimal functionality. 

Follow Mark and Jason as they visit companies and review the equipment to ensure that their gears are made using the best manufacturing processes available.

An exciting update on Hill Helicopters' latest development: Airframe 4. In this video, we get an inside look at the new airframe and learn about the advancements being made in foam and surface application.

Find out why Hill chose this route and how it has been so successful while at the same time proving cost effective. It’s all about striving for the ultimate in streamlining, speed, payload, hover performance and of course safety.

Find out about the technicalities of making aerospace parts and how the engineering team at Hill are maximising the efficiency of gears being made for the HX50, with close-up footage and extensive explanation of the entire process.

Hill perfects its infusion method to turn out its most successful airframe yet, inspiring confidence and enthusiasm from the whole team.

We get a tour of DC2 and an idea of the incredible amount of effort that is going in to perfect the airframe.  A lot has been learned by producing two airframes and this is informing the third version, as the edges and surfaces get smoother and tiny imperfections are eliminated.

Learn about the history behind the decision Hill made to manufacture all of its components in house, and how this system benefits owners with their initial purchase, as well as over the long term.

Hill have been able to demonstrate that their approach to making a monolarge in a single piece not only works, but is remarkably cost-effective. Watch how it’s done, from start to finish.

The news is good for in-house manufacturing of the HX50’s main rotor gear box: find out about the demanding measurements being done on tolerances on our gears, and why it’s so important.

The whole process is demonstrated and explained in detail, with the chance to see the amazing result, inside and out – a fully assembled full-scale HX50 monolarge.

A detailed demonstration of how the HX50’s main rotor gearbox gears are being tested by a company that specialises in this technology, with lots more interesting information on gears in general.

Jason and Mark go on an expedition to look at a very sophisticated machine that will drill thousands of tiny precision holes in fabricated sheet metal components - you can follow along as the meeting, consultation and demonstration unfold.

Hill enter a new stage in production of the HX50 where their CMM testing facility is being set up to test components they are manufacturing as part of their vertical integration strategy. All this is demonstrated in detail by Jason Hill.

Becoming an organisation that’s able to produce really highly technological parts is a massive journey in its own right, quite apart from designing and developing the revolutionary HX50 helicopter. Hill is approaching both with aplomb.

DC2 revolves around everything related to composites and is the future setting for the manufacture of the HX50 fuselage. Then there’s DC3 – an area devoted to the GT50 engine, while DC1 will concentrate on precision engineering. Prepare for a great guided tour!

Jason gives us a clear, comprehensive explanation of what turns a piece of high grade alloy steel into a gear that will withstand the colossal stresses it will be subjected to during its life in service in the GT50 engine.

An impressive demonstration of what the Helimove option will be able to do, accompanied by an explanation by mechanical design engineer Gareth on the importance of establishing what the actual torque values will be in practice.

Tim Gulland, Lead Composites Engineer sets the scene for tests for the seat attenuator with an impressive live demonstration. See how technology first developed for Formula 1 is being adapted to make the HX50 seats not just comfortable but extremely safe.

The fusion experts at Composite Integration have been working hard to produce a one third scale model of the HX50. They explain what a huge challenge this was, and Jason Hill tells us why composites are so crucial to the project.

An exciting new chapter in the HX50 development programme takes off as huge 5-axis and 3-axis CNC machines are installed and commissioned.

The progression that begins with developing the architecture for the structure of the aircraft, followed by a rigorous testing regime to determine the core material properties that any given part will deliver in practice.

An important stage in the HX50 journey is revealed on a visit to the Datum factory where engineers are turning Hill’s design for the fuselage into a one third scale 3D model in preparation for testing.

Jason Hill gives us a fascinating look at how gears are being manufactured for the HX50 engine, while explaining the rationale behind choosing the method being used, and how it fits with the price point that has been achieved.

Jason Hill visits a composites factory to collaborate with the experts on how to solve the trickier aspects of resin infusion composite manufacturing, needed for the one-piece fuselage that has been designed for the HX50.

Join helicopter pilot, engineer and intrepid explorer Steve Brooks in a lively discussion about his record-breaking travels along with reflections on the HX50 and its positive implications for the aviation industry.

Peter Wilson, known for his 3 major expeditions around the world by helicopter, joins Sam to talk about the aviation industry and the positive changes the HX50 is bringing to it.

Filmmaker Sam meets up with Jason Hill for a site visit at a rubber moulding company where components are being custom made for the HX50.