Siemens & JetZero Build All-Wing Z4 Aircraft AI Smart Plant

California-based aviation startup, JetZero, is breaking ground on its first manufacturing and final assembly campus. The facility is situated on a site of more than 600 acres in Greensboro, US.

The project represents a US$4.7bn investment announced last year, with the development set to create more than 14,500 jobs for the region.

The company co-designed the factory with Siemens’ Smart Infrastructure, Electrification and Automation divisions. The partnership allows the manufacturer to leverage industrial AI tools throughout the site.

Scaling commercial aircraft

The Greensboro plant will manufacture the JetZero Z4, an all-wing aircraft designed for the commercial middle market.

The Z4 has a 250-passenger capacity and can operate across a range of up to 5,000 nautical miles.

The aviation company secured investments and conditional purchase agreements for the aircraft. These agreements were signed with Alaska Airlines and United Airlines.

Tom O’Leary, CEO and Co-Founder of JetZero, shares details on the geographic expansion. He says: “It should come as no surprise that JetZero is breaking ground here in North Carolina – the first in flight state. North Carolina has a vision for its future as a global aerospace hub, and JetZero shares that vision. 

“We believe the time has come for an all-wing airplane, to support the industry’s need for more efficient airplanes that also deliver an incredible experience. We intend to reshape aviation, from right here in North Carolina.”

Industrial AI and digital twins power smart manufacturing

The Greensboro site operates as a smart factory. JetZero collaborated with Siemens and Deloitte to design the facility using advanced digital and AI-native platforms.

These systems allowed engineers to build a complete digital twin of the factory before construction began. The digital model simulated how machines, personnel and materials move through the building.

Tom explains the operational benefits of the technology: “By using the best digital tools available before we break ground, we’ve designed a factory that can grow and change with us. That means we can deliver better aircraft, faster, for our customers and our country.”

Ann Fairchild, President and CEO of Siemens USA, highlights the regional economic impact of the project. She says: “Our partnership with JetZero demonstrates how cutting-edge industrial technology can help reindustrialise America. Our digital twins help bring the next generation of manufacturing facilities to life faster and with greater confidence.

“We’re proud to help JetZero build a world-class aerospace facility that will create thousands of jobs and strengthen North Carolina’s position as the next great US aerospace hub.”

Siemens also supports the design, build and test model for the JetZero Demonstrator aircraft. This blended-wing body prototype is funded by a US$235m contract from the Department of Defense awarded in 2023.

Securing US Air Force development deals

JetZero was founded in California in 2021. The startup receives financial backing from high-profile investors, including United Airlines Ventures and Northrop Grumman.

According to JetZero, the largest-ever State-level incentive package for a startup supported the selection of the Greensboro site. The package applies to businesses across all industrial sectors.

North Carolina Governor, Josh Stein, states: “Today, a great new chapter in North Carolina's storied history of flight is taking off. JetZero's decision to build here is a vote of confidence in North Carolina's workforce, our universities and community colleges and our long aerospace tradition. These 14,500 jobs and US$4.7bn in investment will transform the triad region for generations. North Carolina is not only First in Flight, we are the future of flight, too.”

The US Air Force selected the company to design, test and integrate structures for a full-scale demonstrator airplane. This prototype is scheduled to complete its initial flight in 2027.

The manufacturer is also developing military variants of the Z4 aircraft. These designs include a dedicated transport aircraft and an aerial refueler.