Syska and RMW Help Supernal Prepare for Liftoff:
Design R&D Facility for Advanced Air Mobility
Sometimes it’s good to have your head in the clouds.
That’s where Syska and RMW Architects put their heads as they prepared to convert a Silicon Valley warehouse into the R&D headquarters for Supernal, a start-up company that’s developing an electric vertical take-off and landing (eVTOL) vehicle – essentially, an aircraft for personal use. In approaching this complex project, the two firms had to get up to speed on the fast-growing, ever-changing field of advanced air mobility (AAM), sometimes referred to as urban air mobility.
Serving as the engineer of record, Syska provided MEP engineering, fire protection, and architectural lighting. RMW was the project designer and architect of record. They worked closely together and with Supernal to transform the 72,000-square-foot, two-story warehouse into a facility that would meet the functional and aesthetic objectives of Supernal while accommodating its future needs. Here’s how they managed it:
Aesthetics
Startups have a lot of leeway in developing their own branding and design standards; there are no corporate guidelines they must follow. In the case of Supernal, the conceptual design process took place while the company’s brand and cultural identity were developing, reports Jenna Szczech, a senior designer at RMW who served as lead designer for the interior. Each effort influenced the other, resulting in a design philosophy that Supernal describes as a sense of kinship, “which aims to foster community and encourage collaboration among employees.”
“A lot of companies in this realm of high-tech go for futuristic, rigid and hard design with lots of angles and dark colors,” Szczech says. “Supernal wanted a space that feels like home and is welcoming, so although we made sure to keep the sense of the sky and the future, we also brought in natural materials to make the environment comforting.”
According to Supernal, notable features include areas of respite and a mix of individual and collaborative spaces, a gym, rest pods, EV charging stations and meditation rooms, “complemented by panoramic mountain views and the inclusion of greenery and plants throughout, bringing nature into the space.”
“Supernal wanted a space that feels like home and is welcoming, so although we made sure to keep the sense of the sky and the future, we also brought in natural materials to make the environment comforting.”
Jenna Szczech, Senior Designer, RMW
“We wanted to understand exactly what they are trying to do and what their testing involves so we could build the infrastructure that meets their needs both now and in the future...”
Sami El Khoury, Project Manager, Syska Hennessy
Functionality
As you can see from this Supernal video, the space looks gorgeous. But it also supports the essential function of battery testing and research. This double achievement stems from RMW’s and Syska’s own research, which involved extensive discussions with Supernal employees. “We wanted to understand exactly what they are trying to do and what their testing involves so we could build the infrastructure that meets their needs both now and in the future,” says Syska’s Sami El Khoury, who served as project manager.
“We had to speak owner,” adds Robert Fagnant, Syska associate principal, who oversaw the architectural lighting services. “We had to understand why the research is so important for their mission. If you don’t understand this, you basically end up with a bike with a broken spoke.”
Terry Kwik, partner at RMW, says the team quickly learned just how critical the battery research was for Supernal and for the air mobility industry overall. “These guys are producing flying cars, and you can’t use the same batteries that you use in an electric car because they’re way too heavy. So everybody is looking for the next latest and greatest battery chemistry – lighter weight, but more power-dense.”
Latest and greatest means constant change, too. The battery technology Supernal was using at the outset of the project is completely different from the technology it uses now, only a few years later. Recognizing that this rapid pace of change is the industry norm, Syska made sure its systems could accommodate further changes to battery technology and to Supernal’s size and business objectives. As Robert points out, all of Supernal’s facilities “will be in constant flux.”
Stan Lew, President of RMW, notes that the many discussions with Supernal allowed the team to figure out what to do about power from the utility provider, which was insufficient for testing and discharging batteries. “We worked closely with the users to determine ways to bring power on sensibly while negotiating with a utility whose services are completely outside of our control,” he says.
As a result of these discussions, Syska developed an unusual way to address the unmet power needs – a microgrid system. This system stores the power dissipated by the testing equipment and sends it back to the facility. That reused energy can power the facility’s AC or lighting. Power struggle resolved.
“We worked closely with the users to determine ways to bring power sensibly while negotiating with a utility whose services are completely outside of our control.”
Sten Lew, President, RMW
“It’s definitely a partnership. We talked constantly for this project. We talked about things like achieving a clean, open ceiling that accommodates all of the ductwork and integrates with the lighting concepts.”
Jenna Szczech, Senior Designer, RMW
Communication and Collaboration
The complexity of the project required extensive collaboration and ongoing communication between RMW and Syska. Fortunately, the firms have worked together many times in the past, and they know how to do so effectively.
Terry remembers being introduced to Jose Herrera, Syska’s principal in charge for the Supernal project, many years ago: “Jose asked me, ‘Terry, who’s your go-to MEP firm?’ I gave him a name and he said, ‘You know what? Syska’s going to be your new go-to MEP.” Terry has never forgotten this conversation, and he says that in the years since the two firms regularly find ways to work together, whether RMW has the relationship with the client or Syska does. In Supernal’s case, both had worked with the client before, and the client asked RMW to bring Syska on board. The request made all parties happy.
“It’s definitely a partnership,” says Jenna. “We talked constantly for this project. We talked about things like achieving a clean, open ceiling that accommodates all of the ductwork and integrates with the lighting concepts.” Sami credits the unblocked view in the mezzanine to these conversations. “We had to position the ducts as high as we could so that nothing interfered with the visibility that RMW wanted,” he says.
“What’s fantastic about working with Syska is the team’s flexibility, which is so important when R&D goals change at a moment’s notice,” Terry comments. He recalls many times when Syska’s electrical team had to recircuit everything because of a change in equipment specs, not to mention the development of the microgrid. “Syska always comes through,” he states.
Jose feels the same way about RMW. “We’re not siloed as engineers and architects,” he says. “We’re working as a team and finding a solution for the client.”
Outcomes
Supernal liked the Silicon Valley design so much that it hired RMW and Syska for two additional projects, both located in Irvine. One is a 105,6000-square-foot office and the other is an 80,000-square-foot structure where design, manufacturing, and testing of aircraft takes place.
Despite the differences in size and purpose, the two Irvine buildings share some similarities with the Silicon Valley facility. “When you tour the spaces, you think to yourself that it feels and looks like Supernal,” says Robert. “RMW has created a design language through architecture, interior design, and lighting that you pick up on.” “The design and the work that went into this facility became something of a guidepost for future projects,” Stan confirms. “They set the tone for other Supernal facilities.”
Jenna has visited and worked at all three locations since completion and enjoys hearing feedback from Supernal employees. “It’s so fulfilling to learn that they find the space welcoming and comfortable to work in,” she reports.
The team hopes to complete more projects for Supernal in the future. “It’s fun to be able to come up with a space that amazing, bright people will use to develop flying cars,” says Jose. Stan adds: “We’re excited to help shape the future of advanced air mobility. When these vehicles are taken to the sky, we’ll have had a hand in history-making.”