I was given an exclusive glimpse inside world-leading Wolverhampton aerospace factory after French takeover

The operation at Fordhouses has undergone a complete rebrand since Safran acquired Collins Aerospace in a £1.3 billion deal that was announced on July 21 that has brought together the best-in-class hydraulic and mechanical actuation capabilities of Collins Aerospace with Safran’s strong know-how in electro-mechanical actuation and electronics.

The acquisition has made Safran a global leader in flight control and actuation systems and well-positioned for next-generation platforms, which company bosses proudly gave a brief peek at on December 2 as CEO Franck Saudo visited the Wolverhampton facility - which was originally H.M. Hobson Ltd before being acquired by Lucas Aerospace in 1970 and later Goodrich and UTC, then Collins Aerospace.

Around 1,500 people are today employed at the 500,000 sq ft site, which was first purchased in 1939 by Hobson Ltd which began producing carburetor bodies and fuel systems for the Hercules engine. It is positioned close to junction two of the M54 and takes in employees from Shropshire and Staffordshire as well as the Black Country.

“There’s a lot of history and heritage here,” general manager John England said before showcasing the company’s ground-breaking work to produce aircraft technology for the future.

The tech giant, the third largest aerospace company in the world with revenues of £1.5 billion in 2025 and around 4,000 employees worldwide, is busy working on revolutionary new thin wing technology for single-aisle commercial aircrafts of the future that will be increasingly electrified to meet carbon reduction goals.

Thinner, lighter and longer wings are expected to reduce fuel consumption by 10 to 15 per cent, but they will need to fold up to fit into current airport structures that are in place and this will require more actuators on aircraft to make the necessary adjustments as the plane starts and ends its journey.

Engineering senior director Phil Bircham said: “The wings of tomorrow are going to look a lot different with double the number of actuators. It’s breakthrough technology.”

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Engineers highlighted how the aircraft of the future will have more electric and fewer hydraulic processes - about 50-50, up from around 16 per cent on a current Boeing 787.

Mr Bircham said: “It’s going to be quite a leap forward to go up to 50 per cent electric. For next generation aircraft it will probably be closer to 100 per cent. It’s a step change.”

Testing is heavily underway with the goal of having proven and perfected technology ready by 2028, with the modern, new aircrafts expected to be in the skies by the mid 2030s.

Chief engineer John Derry explained: “The wings have got to change dramatically - they’re going to be much longer and thinner - four to five metres each wing - and we’re going to have to make smaller actuators and more actuators. The current maximum width is 36 metres to make sure there’s room for fuel trucks and fire trucks. 

"If aircraft are 45 metres wide you’re going to have to fold up large chunks of the wing. We’re already developing this system but we need them designed, made, tested and proven before customers launch their next aircraft programme by around 2028.”

The company’s work for the defence industry, creating missile actuation systems for military jets, was also not off limits…although I had my phone cameras securely taped over to ensure no unauthorised images were taken.

Production for the defence sector is set to be ramped up, I was told, having already increased by around 40 per cent in the last 12 months.

Safran bosses were also keen to showcase the Wolverhampton site's £16 million automated bevel gear manufacturing centre with lights out capability, which means it can operate fully autonomously without a human in the building.

The centre, which offers a glimpse into the future of fully automated workshops, was developed thanks to partnership working with universities and major aerospace names.

Despite the technological advancements that mean certain manufacturing functions can be performed robotically without humans, one of Safran's key aims is to 'continue to build an outstanding place to work'. 

Safran is aware of the importance of Wolverhampton to its operation and says it wants to maintain the factory's contribution to the city and the winder West Midlands.

Bosses at the Wolverhampton site, one of the largest manufacturing employers in area, said some employees have completed more than 50 years with the business which lists Boeing, Airbus, Lockheed Martin and Raytheon among its major customers and the Ministry of Defence as a key partner.

A total of 113 staff are currently on early career schemes for apprentices and graduates, with around 45 more expected to join in 2026.

“We’re immensely proud to partner with teams here in Wolverhampton,” CEO Franck told me during the whistlestop tour of the site where pioneering work to keep the world safe and connected is quietly taking great strides forward.