The Hybrid Electric Regional Aircraft Distribution Technologies (HECATE) Clean Aviation project will mature and develop breakthrough technologies and perform scalability and impact analysis to ensure safe and power-dense technologies that will enable Entry Into Service (EIS) of hybrid-electric regional aircraft by 2035. Along the project, a circular economy approach in future aircraft will be ensured through the use of Life Cycle Assessment (LCA), performing this type of assessment on the overall electrical system and primary/secondary distribution and conversion technologies, helping to be in line with long-term environmental roadmaps such as Flightpath 2050. This communication includes a description of the HECATE activities and how LCA will be applied to the future Regional Aircraft Electrical Distribution System.

This article presents a comprehensive analysis of the primary electrical power distribution system in hybrid-electric aircraft, with particular emphasis on its environmental performance assessed through Life Cycle Assessment (LCA). High-resolution Life Cycle Inventory (LCI) data were developed in collaboration with industry partners and refined to reflect current production standards. The results indicate that printed circuit boards (PCBs), magnets, precious metals (gold and silver), and copper are the primary contributors to environmental impact, with PCBs alone accounting for over 50% of material-related emissions. Although precious metals constitute only 0.014% of the product’s mass, they account for nearly 9% of total emissions due to the energy-intensive nature of their mining and refining processes. Additionally, manufacturing stages involving thermal treatments—such as surface coating of iron cores at 850 °C for 14 h—significantly increase energy consumption and associated emissions. The study concludes with recommendations for reducing the carbon footprint of future aircraft power systems through improved material efficiency, process optimization, and supply chain sustainability.