Future Plant.

Stavatti is planning a new-build Aircraft Manufacturing and Assembly Plant of two million square feet. The plant is conceived as a future world headquarters and primary design and manufacturing center: a greenfield facility at a controlled airport with a paved runway of at least 9,000 by 150 feet, sized for SM-920 airworthiness certification, flight test, and delivery.

9400 Porter Road in Niagara Falls remains Stavatti’s Prototyping and Development Center. The hangar there can accommodate SM-100 and SM-920 prototype aircraft. Full-rate production of the SM-31 Stiletto, SM-39 Razor, SM-100 Transport, SM-150 Sportplane, SM-920 Airliner and additional types requires dedicated floor area the Niagara campus was never meant to provide. The Future Plant is that next facility.

A circular engineering, machining, and leadership rotunda sits at the center. Three assembly hangars radiate from it, each 300 feet wide with doors 200 by 60 feet, so several aircraft types can be built in parallel under one roof. The first wing can be a 300,000 square foot module that operates as a stand-alone production center before the remainder of the campus is completed.

The floor is designed around aluminum-lithium foam-metal sandwich structure: friction-stir and laser welding, six-axis robotic cells, abrasive waterjet, additive manufacturing, hydroforming, and a 15 by 50 foot autoclave for high-temperature composites. Production is AI-directed. People remain in the loop for engineering, quality, and flight.

Stavatti is identifying candidate sites in the United States and is working directly with communities, airports, and economic-development authorities to make the plant a reality. Additional plants may follow in Asia, the Middle East, and Europe to serve regional demand. Ground-breaking will be announced when a site is selected.