Founded in 2020 by British engineer Jason Hill, Hill Helicopters has established itself as a true disruptor in the highly regulated aerospace industry. Its goal: to design a luxurious, high-performance helicopter entirely developed in-house — a unique industrial strategy in the sector. At the heart of this innovative approach, PTC solutions, especially Creo and Windchill, play a key role. We spoke with Serge Romano, VP of Product Experience at PTC, who shared more about the concept.
A Unique Industrial Concept
The HX50, the brand’s first model, stands out for its sleek design, premium comfort, and cutting-edge performance. Unlike traditional manufacturers that rely heavily on subcontracting, Hill Helicopters has chosen to design and manufacture everything in-house — from avionics and the turbine to the carbon fiber fuselage and onboard electronics.
As Serge Romano from PTC points out:
“Even the ball bearings… they design and manufacture them in-house.”
It’s a bold but controlled strategy, aiming to reduce costs, maintain strict quality control, and offer a helicopter at an unprecedented price — around €650,000, compared to over a million euros for competitors.
“If you do everything in-house, you have full control over production costs… It means they’re taking on more risk, but it will allow them to enter the market at a much lower price point with a far more advanced helicopter.”
A Design Driven by Innovation
To bring this ambitious project to life, Hill relies on PTC tools — Creo for 3D design and Windchill for product data management — from the first sketches through to complex iterations.
A concrete example? The redesign of the tail rotor, decided mid-development to reduce noise, and improved using PTC’s Generative Design tools:
“They figured they could reduce noise by slowing down the tail rotor blades… This meant changing the geometry of each blade, and the gear system had to be completely redesigned. It was a perfect example for us at PTC, showing how our tools can be used for this kind of change.”
These adjustments were made quickly, optimizing both performance and component durability.
Towards Full Digital Continuity
Beyond design, Hill Helicopters plans to expand its use of PTC solutions for requirements management (Codebeamer) and after-sales service (ServiceMax). With partners like Ansys for mission simulation, PTC is gearing up to offer a product fully tailored for the digital era — from design to maintenance.
“We’re looking at all the ways Hill Helicopters could leverage various solutions to ensure full digital continuity in product development.”
First Flight Scheduled for December 2025
The schedule is ambitious: turbine testing is imminent, and the HX50’s first flight is planned for December 2025. For Serge Romano, Hill Helicopters is a company to watch closely:
“It will be very interesting to follow the evolution of this company.”
Perhaps we’ll even see them at next year’s Farnborough International Airshow.
