Samson Sky is revealing details of its new manufacturing process, which will enable it to produce its carbon fiber parts eight times faster and at half the cost of traditional carbon fiber parts.
At the center of Samson’s manufacturing system is their Builder Assist Program, designed to help customers meet the FAA’s 51% construction requirement for Experimental Category aircraft. Instead of needing specialized skills, customers use computer-guided machinery to fabricate their parts, ensuring accuracy and efficiency. The final assembly is then completed by Switchblade technicians, guaranteeing precision and quality throughout the process.
Switchblade Flying Sports Car is a street-legal, hybrid-electric vehicle that offers high performance on both the road and in the air. It can be parked in a home garage and driven to a nearby airport using highways and local roads. Once there, its wings swing out and the tail extends in under three minutes. You can then fly your registered aircraft to the airport nearest your destination, land, switch back to driving mode, stow the wings and tail safely, and drive the last few miles.
The two-seat Switchblade has room for travel bags and can fly up to 450 miles on a single tank of premium auto gas, with an estimated cruise speed of 160 mph.
Company officials stated that due to their new program, they have cut their original projection of the customer’s time commitment from over three weeks down to just one week at the Build Center.
Sam Bousfield, CEO and designer of the Switchblade, stated, “Our high-tech system saves owners time and money while giving them the unique experience of building their own vehicle.
“Part of our purpose is to transform travel while reducing our footprint on the earth. With our system, we’ve created a scalable model for producing high-performance parts with a fraction of the environmental impact of traditional methods.”
With over 2,400 Reservation Holders across 50+ countries and all 50 U.S. states, Samson is preparing for large-scale production, aiming to deliver the first Switchblades in 2026.
In contrast to other Builder Assist programs, which often require weeks or even months of hands-on work, Samson’s automated manufacturing and simplified tasks allow participants to complete their portion in just one week or less at a Builder Assist Center. The company expects this breakthrough in efficiency to attract even more customers, making the dream of owning a flying car more accessible.
