AIRCO has opened a new manufacturing and integration facility in Pennsylvania to scale production of its modular synthetic fuel systems.
AIRCO has opened a new manufacturing and integration facility in Pennsylvania to scale production of its modular synthetic fuel systems, as interest in deployable fuel generation technologies for military operations grows.
The New Britain site will serve as the company’s primary manufacturing base, bringing engineering, research, operations, and production under one location.
Work will focus on AIRCO’s Mobile, Adaptable, and Dynamic (MAD) Fuel System, a containerized platform designed to produce synthetic fuel at the point of use rather than relying on conventional fuel delivery networks.
The concept is aimed at operational environments where fuel transport is difficult, costly, or vulnerable to disruption, a long-standing logistical challenge in expeditionary military operations.
"For over a century, fuel has been produced in centralized refineries and shipped around the world. We’re changing that," said Gregory Constantine, Co-Founder and CEO of AIRCO.
"This facility enables us to manufacture autonomous systems that produce fuel anywhere, on demand. It’s a fundamental shift from fuel as a commodity to fuel as infrastructure."
The MAD (Mobile, Adaptable, and Dynamic) Fuel System. Photo: AIRCODynamic Fuel Technology
Housed in two 40-foot (12-meter) containers, the MAD system uses a power-to-liquid conversion process that combines captured carbon dioxide with hydrogen to produce synthetic jet fuel or diesel.
According to the company, the output is a drop-in fuel compatible with existing aircraft and ground vehicles, eliminating the need for platform modifications.
The modular system is being developed with increasing automation to reduce onsite manpower requirements and enable more autonomous operation in remote locations.
Development has received backing from the US Air Force through AFWERX’s Strategic Funding Increase program, which supports the transition of emerging technologies toward operational deployment.
AIRCO aims to deliver its first deployable unit in 2027.
