This technical article examines how engineers can leverage modern manufacturing execution approaches to break down silos, improve collaboration, and maintain alignment between as-designed and as-built products. The result: faster ramp-up, fewer errors, and greater efficiency.

Inside, you’ll learn about:

• Why traditional disconnected systems create delays and errors
• How visibility, integration, and automation accelerate production
• The importance of digital continuity between design and execution
• Real-time monitoring and corrective actions to keep programs on track
• Ways to prepare operations for next-gen technologies like IoT, AR/VR, and additive manufacturing

Your download is sponsored by Siemens.

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This eBook explores how aerospace and defense manufacturers can utilize closed-loop manufacturing to enhance collaboration, expedite time-to-market, and ensure quality across complex programs. It demonstrates how digital continuity connects design, planning, and execution — transforming raw data into actionable insights.

Inside, you’ll learn about:

• Reducing engineering change implementation from weeks to hours
• Improving collaboration between shop floor teams and engineering
• Using digital twins and digital threads for accuracy and speed
• Accelerating new product introductions and adapting to change orders
• Driving continuous improvement with real-time, closed-loop feedback

Your download is sponsored by Siemens.

The post The Digital Future of Aerospace and Defense Manufacturing appeared first on Engineering.com.

According to the company, the new approach to manufacturing solar array substrates reduces composite build times by up to six months, amounting to a 50 percent improvement compared to conventional techniques. As part of its announcement of the new technology, Boeing has stated that flight-representative hardware utilizing this technology has already completed engineering testing and is currently progressing through the company’s standard qualification process.

The first 3D-printed solar arrays will fly Spectrolab solar cells aboard small satellites built by Millennium Space Systems. Both of these non-integrated subsidiaries are part of Boeing’s Space Mission Systems organization.

“By integrating Boeing’s additive manufacturing expertise with Spectrolab’s high‑efficiency solar tech and Millennium’s high‑rate production line, our Space Mission Systems team is turning production speed into a capability, helping customers field resilient constellations faster,” said Michelle Parker, vice president of Boeing Space Mission Systems, in a press release.

Boeing also claims that this approach enables a parallel build of the complete array, pairing a printed, rigid substrate with modular solar technologies. The company avers that 3D printing features such as harness paths and attachment points directly into each panel replaces dozens of separate parts, long‑lead tooling, and delicate bonding steps. The result is one strong, precise piece that is faster to build and easier to integrate.

“By pairing qualified materials with a common digital thread and high‑rate production, we can lighten structures, craft novel designs, and repeat success across programs,” said Melissa Orme, vice president of materials and structures for Boeing Technology Innovation. “That’s the point of enterprise additive, it delivers better parts today and the capacity to build many more of them tomorrow.”

In total, Boeing claims to have integrated more than 150,000 additive parts into its products, including more than 1,000 radio frequency parts on each Wideband Global SATCOM satellite. The new array approach is also intended to scale to larger platforms, including the Boeing 702-class spacecraft slated for release next year

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This is why the editors at Engineering.com designed our Digital Transformation Week event—to help engineers unpack all the choices in front of them, and to help them do it at the speed and scale required to compete.

Join us for this series of lunch hour webinars to gain insights and ideas from people who have seen some best-in-class digital transformations take shape.

Registrations are open and spots are filling up fast. Here’s what we have planned for the week:

September 22: Building the Digital Thread Across the Product Lifecycle

12:00 PM Eastern Daylight Time

This webinar is the opening session for our inaugural Digital Transformation Week. We will address the real challenges of implementing digital transformation at any scale, focusing on when, why and how to leverage manufacturing data. We will discuss freeing data from its silos and using your bill of materials as a single source of truth. Finally, we will help you understand how data can fill in the gaps between design and manufacturing to create true end-to-end digital mastery.

September 23: Demystifying Digital Transformation: Scalable strategies for Small & Mid-Sized Manufacturers

12:00 PM Eastern Daylight Time

Whether your organization is just beginning its digital journey or seeking to expand successful initiatives across multiple departments, understanding the unique challenges and opportunities faced by smaller enterprises is crucial. Tailored strategies, realistic resource planning, and clear objectives empower SMBs to move beyond theory and pilot phases, transforming digital ambitions into scalable reality. By examining proven frameworks and real-world case studies, this session will demystify the process and equip you with actionable insights designed for organizations of every size and level of digital maturity.

September 24, 2025: Scaling AI in Engineering: A Practical Blueprint for Companies of Every Size

12:00 PM Eastern Daylight Time

You can’t talk about digital transformation without covering artificial intelligence. Across industries, engineering leaders are experimenting with AI pilots — but many remain uncertain about how to move from experiments to production-scale adoption. The challenge is not primarily about what algorithms or tools to select but about creating the right blueprint: where to start, how to integrate with existing workflows, and how to scale in a way that engineers trust and the business can see immediate value. We will explore how companies are combining foundation models, predictive physics AI, agentic workflow automation, and open infrastructure into a stepped roadmap that works whether you are a small team seeking efficiency gains or a global enterprise aiming to digitally transform at scale.

September 25: How to Manage Expectations for Digital Transformation

12:00 PM Eastern Daylight Time

The digital transformation trend is going strong and manufacturers of all sizes are exploring what could be potentially game-changing investments for their companies. With so much promise and so much hype, it’s hard to know what is truly possible. Special guest Brian Zakrajsek, Smart Manufacturing Leader at Deloitte Consulting LLP, will discuss what digital transformation really is and what it looks like on the ground floor of a manufacturer trying to find its way. He will chat about some common unrealistic expectations, what the realistic expectation might be for each, and how to get there.

The post Register for Digital Transformation Week 2025 appeared first on Engineering.com.

GE Aerospace and South Burlington, Vermont-based Beta Technologies Inc. have struck a strategic partnership to accelerate the development of a hybrid electric turbogenerator for advanced air mobility (AAM).

Applications include long-range Vertical Takeoff and Landing (VTOL) aircraft and future Beta aircraft and will combine Beta’s permanent magnet electric generators with GE Aerospace’s turbine, certification and safety expertise for large-scale manufacturing. This hybrid solution will leverage existing infrastructure and capabilities, such as GE Aerospace’s CT7 and T700 engines.

As part of the deal, GE Aerospace will make an equity investment of $300 million in Beta. GE Aerospace will have the right to designate a director to join Beta’s Board.

“Partnering with Beta will expand and accelerate hybrid electric technology development, meeting our customers’ needs for differentiated capabilities that provide more range, payload, and optimized engine and aircraft performance,” said GE Aerospace Chairman and CEO H. Lawrence Culp.

The deal is part of GE Aerospace’s pursuit of a suite of technologies for the future of flight, including integrated hybrid electric propulsion systems and advanced new engine architectures.

“We believe the industry is on the precipice of a real step change, and we’re humbled that GE Aerospace has the confidence in our team, technology, and iterative approach to innovation to partner with us. We look forward to partnering to co-develop products that will unlock the potential of hybrid electric flight, and to do it with the rigor, reliability, and safety that aviation demands,” said Kyle Clark, Beta Technologies’ Founder and CEO.

Beta’s “Alia” five-passenger VTOL and conventional electric aircraft charge in less than an hour, according to Beta’s website. They are engineered for all-weather performance and have been tested to operate reliably in a wide range of environmental conditions across the U.S. and Europe. ALIA’s electric propulsion and battery systems — which are developed in-house — offers reliable, high-tempo performance, as well as a quieter sound profile than conventional aircraft.

GE Aerospace and Beta also announced the two companies will collaborate to develop an additional offering for the AAM industry but offered no additional details.

The post GE Aerospace teams with Beta Technologies on hybrid electric plane engines appeared first on Engineering.com.

The report says North American companies ordered 17,635 robots valued at $1.094 billion in the first six months of 2025. Automotive OEMS led with a 34% year-over-year increase in units ordered. Other top-performing segments included plastics and rubber (+9%) and life sciences/pharma/biomed (+8%).

In Q2, companies ordered 8,571 robots worth $513 million, marking a 9% increase in units compared to Q2 2024. Life sciences/pharma/biomed posted the strongest sector growth in the quarter (+22%), followed by semiconductors/electronics/photonics (+18%) and steady gains in plastics, automotive components, and general industry.

 “It’s not just about efficiency anymore. It’s about building resilience, improving flexibility, and staying competitive in a rapidly changing global market. If these patterns hold, the North American robotics market could outperform 2024 levels by mid-single digit growth rates by the end of the year,” said Alex Shikany, Executive Vice President at A3.

Cobots’ rising influence

Collaborative robots (cobots) accounted for a growing share of the market with 3,085 units ordered in the first half of 2025, valued at $114 million. In Q2, cobots made up 23.7% of all units and 14.7% of revenue. These systems work safely alongside humans and address automation needs in space- or labor-constrained environments. A3 began tracking cobots as a distinct category in Q1 2025 and will expand future reporting to include growth trends by sector.

Automotive versus non-automotive sectors

The non-automotive sector took the lead over automotive in Q2, accounting for 56% of total units ordered. This move reflects the expanding role of automation in industries such as life sciences, electronics, and other non-automotive manufacturing sectors.

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ASTM International (formerly the American Society for Testing and Materials) is a global organization that develops standards for materials, products, systems and services across multiple industries. While the organization has numerous standards related to aviation and aerospace, here are some key sustainability-related standards:

• D7566 (Standard Specification for Aviation Turbine Fuel Containing Synthesized Hydrocarbons
• E3027 (Standard Guide for Making Sustainability-Related Chemical Selection Decisions in the Life-Cycle of Products)
• E3096 (Standard Guide for Definition, Selection, and Organization of Key Performance Indicators for Environmental Aspects of Manufacturing Processes)
• E2986 (Standard Guide for Evaluation of Environmental Aspects of Sustainability of Manufacturing Processes)
• E2979 (Standard Classification for Discarded Materials from Manufacturing Facilities and Associated Support Facilities)
• E3012 (Standard Guide for Characterizing Environmental Aspects of Manufacturing Processes)
• E3200 (Standard Guide for Investment Analysis in Environmentally Sustainable Manufacturing)
• E3461 (Standard Guide for Principles of Circular Product Design)
• F2931 (Standard Guide for Analytical Testing of Substances of Very High Concern in Materials and Products)

ASTM also has numerous standards not directly related to sustainability, but related to advanced aerospace materials such as polymer composites, aluminum alloys and titanium alloys. For example, D3039/D3039M-17 (Tensile Properties of Polymer Matrix Composite Materials) is one of several standards related to composite materials.

EASA

The European Union Aviation Safety Agency (EASA) works with the European Commission to implement ICAO standards into EU legislation. The EASA has published numerous regulations related to environmental and sustainability issues, such as Article 9 and Article 19 of the Basic Regulation, Annex II (Part-21) of the Implementing Regulation, and the Certification Specifications of CS-34 (emissions), CS-36 (noise) and CS-CO₂ (CO₂ Emissions). EASA launched its Sustainable Aviation Programme in 2020 in coordination with environmental protection regulations (EU2018/1139, Art. 87) and the European Green Deal. A subsequent EU regulation commonly known as the ReFuelEU Aviation Regulation was published as part of a legislative package aimed at reducing net greenhouse gas emissions by at least 55% by 2030, compared to 1990 levels. 

GRI

The Global Reporting Initiative (GRI) develops standards for organizations to report on their environmental and social impacts. The GRI Standards are subdivided into three categories:

• Universal Standards — Reporting on human rights and environmental due diligence, in line with intergovernmental expectations, applicable to all organizations
• Sector Standards  — Reporting on sector-specific impacts, with aerospace and defense one of 40 sectors
• Topic Standards — Disclosures relevant to a particular topic

IATA

The International Air Transport Association (IATA)  and its members committed to a target of achieving net-zero CO₂ emissions by 2050. As part of that initiative, IATA released the Sustainable Aviation Fuel (SAF) Matchmaker platform, which aids SAF procurement between airlines and SAF producers. The IATA’s Airline Sustainability Reporting Handbook (ASRH) provides guidance on GRI-based reporting, subdivided into eight topics:

• Conduct and compliance
• Customer experience
• Energy and emissions
• Labor conditions
• Noise
• People and development
• Supply chain sustainability
• Waste and effluents

ICAO

The International Civil Aviation Organization (ICAO) develops international standards for aircraft noise, emissions, and fuel venting. For example, the ICAO adopted a CO₂ emissions certification standard: Annex 16, Volume III – Aeroplane CO₂ Standard (2017) that applies to subsonic jet and turboprop airplanes that are new type designs from 2020. It also applies to in-production airplanes from 2023 that are modified and meet a specific change criteria.  This is followed by a production cut-off in 2028, which means airplanes that do not meet the standard can no longer be produced beyond 2028 unless the designs are modified to comply with the standard.

ISO

The International Organization for Standardization (ISO) is a global organization that publishes a wide variety of standards on products and processes. It publishes standards on quality, environmental management and industry-related topics, including the following related to aerospace and other industries:

• ISO 9001 (Quality management systems)
• ISO 14001 (Environmental management systems)
• ISO 15388 (Space systems — Contamination and cleanliness control)
• ISO 23312 (Space systems — Detailed space debris mitigation requirements for spacecraft)
• ISO 24113 (Space systems — Space debris mitigation requirements)

NATA

The National Air Transportation Association (NATA) developed its Sustainability Standard for Aviation Businesses, focusing on reducing greenhouse gas emissions and promoting environmentally friendly practices. The NATA initiative was created to provide fixed base operators (FBOs) and other aviation businesses a self-certification process for pursuing flexible, cost-effective options to lower their carbon footprint by reducing greenhouse gas (GHG) emissions, increasing use of more environmentally friendly energy sources, reducing waste and encouraging sustainability operation-wide.

SASB and IFRS

The Sustainability Accounting Standards Board (SASB) developed standards for disclosing environmental, social and governance information for 77 industries, including aerospace and defense, air freight and logistics and airlines. The standards offer metrics for comparing performance across organizations, identifying sustainability disclosure topics relevant to each industry. The SASB Standards are maintained by the International Sustainability Standards Board (ISSB), following the SASB’s merger with the International Integrated Reporting Council (IIRC) and subsequent consolidation into the IFRS Foundation.

SAE

The Society of Automotive Engineers (SAE) is a global association of engineers and related technical experts in the aerospace, automotive and commercial-vehicle industries. It publishes numerous standards, including Aerospace Material Specifications (AMS), which are specifically related to aerospace and defense. A small sampling of aerospace-related standards include:

• AS9100D (Quality Management Systems – Requirements for Aviation, Space, and Defense Organizations) includes ISO 9001 quality management system requirements and specifies additional aviation, space and defense industry requirements, definitions and notes.
• AMS1428M (Fluid, Aircraft Deicing/Anti-Icing, Non-Newtonian (Pseudoplastic), SAE Types II, III, and IV)
• AMS3143D (Powder Coating Material)
• AIR4766/2A (Airborne Chemicals in Aircraft Cabins)

In 2022, SAE and the International Aviation Waste Management Association (IAWMA) formed a joint committee, G-36 Sustainable Waste Management, to develop standards and best practices for products, processes and services in global commercial and business aviation, airports and flight kitchens. SAE also publishes a wide variety of standards related to aerospace and aviation, but not directly related to sustainability, such as DO-178, DO-278, and DO-330, which focus on the development and certification of software for safety-critical aviation systems.

Other initiatives

In addition to numerous regulations and standards, other organizations have launched initiatives and provided guidelines related to sustainability.

• The Federal Aviation Administration (FAA), along with aircraft manufacturers and airlines, developed the Continuous Lower Energy, Emissions, and Noise (CLEEN) Program, which provides funding to develop and accelerate the introduction of technologies that will reduce noise, emissions, and fuel burn. FAA has also launched initiatives related to sustainable airports.

• The United Nations Committee on the Peaceful Uses of Outer Space (UNCOPUOS) developed 21 guidelines for the long-term sustainability of outer space activities (LTS), which were subsequently endorsed by General Assembly resolution 74/82. The Committee established a new LTS 2.0 working group and five-year workplan in 2022 for continued institutionalized dialogue on issues related to the implementation and review of LTS guidelines.

• Professional associations, such as the Aerospace Industries Association (AIA), American Institute of Aeronautics and Astronautics (AIAA), American Society of Civil Engineers (ASCE), American Society of Civil Engineers (ASME), Institute of Electrical and Electronics Engineers (IEEE), and Society of Military Engineers (SAME), have launched initiatives and published guidance documents related to sustainability.

The wide range of organizations involved in sustainability creates numerous standards, regulations and guidelines, many of which undergo ongoing reviews and changes. It is the responsibility of aerospace industry professionals to stay updated with ongoing developments and how those developments might affect current and future practices.

The post What regulations or standards govern sustainable practices in aerospace? appeared first on Engineering.com.

Since World War II, the heavy tank has been king on the battlefield, combining power, mobility with protection for its crew. The war in Ukraine however, has turned the notion of the powerful, heavily armored main battle tank as the spearhead of the assault, on its head. Cheap, simple drones are destroying large numbers of tanks on the battlefield, and they’re doing it with relatively small explosive warheads. Can tanks be redesigned with sufficient passive protection to withstand a future battlefield teeming with attack drones?

In Ukraine, the answer is no, but the future will likely involve smaller, faster, automated tracked fighting vehicles, and probably drones tasked specifically with defending against other drones. In the future, quality appears to be winning over quantity. 

***
Access all episodes of End of the Line on Engineering TV along with all of our other series.

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Advanced materials

The use of advanced materials, such as aluminum alloys and titanium alloys, can reduce aircraft weight and improve efficiency compared to steel and other traditional materials. Composite materials made from carbon fibers, bio-based materials and polymers offer similar advantages, as well as high strength-to-weight ratios and resistance to fatigue and corrosion. Recycled materials — both metallic and non-metallic — can conserve resources and reduce waste.

Sustainable fuels

Sustainable aviation fuels (SAF) from renewable sources such as biomass and repurposed waste materials can reduce reliance on fossil fuels and reduce CO₂ emissions. The International Air Transport Association (IATA) estimates that SAF could contribute approximately 65% of the reduction in emissions needed by aviation to reach net-zero CO₂ emissions by 2050, a commitment agreed to by IATA member airlines in 2021. Hydrogen fuel cells (HFC) and hydrogen combustion engines are also being researched as alternatives.

Advanced propulsion systems

Electric and hybrid-electric propulsion systems can reduce reliance on fossil fuels and reduce CO₂ emissions. They also reduce noise when compared with conventional aircraft.

Electric propulsion systems generate electricity via onboard energy storage systems such as batteries and use electric motors to drive propellers or turbines. Due to battery charging requirements and related trip-range limitations, early applications of electric propulsion systems have been focused on shorter distances (e.g., 100 miles) to deliver freight and feed passengers into larger airports. The National Aeronautics and Space Administration (NASA) predicts that electrified aircraft propulsion (EAP) technologies will be implemented in commercial aircraft by 2035.

Hybrid systems use a combination of electric motors and internal combustion engines to propel aircraft, offering increased flight ranges compared to pure electric aircraft. The two energy sources may work in parallel or series. Turboelectric systems use gas turbines to generate electricity for electric motors.

Solar-powered aircraft use solar panels to capture energy and batteries or HFC to store the energy. While conventional passenger or cargo applications have not yet been adopted due to power limitations, solar-powered uncrewed aerial vehicles (UAVs) have been used for telecommunications, imagery and other applications.

Electric propulsion, in conjunction with vertical take-off and landing (VTOL) technology, is being considered to power aircraft that can take off and land vertically without a runway. These aircraft could be used for applications such as on-demand air taxi services, regional mobility and freight delivery.

Digital design and engineering technologies

Advanced digital technologies have enabled engineers and other designers to work more efficiently, optimize designs and improve aircraft characteristics, such as aerodynamics and fuel efficiency. Computer-aided design, once considered state-of-the art, has advanced and been joined by other technologies, such as digital twins — digital replicas of physical objects such as manufactured products or facilities. Digital twins supplement detailed 3D models with a wealth of metadata and other information to help engineers and manufacturing teams improve designs and facility operations and maintenance (O&M).

Computer-based simulation enables systems and components to be modeled and analyzed in 3D environments without building full-scale prototypes. These simulations aid design optimization for both aerospace products and manufacturing facilities, helping engineers produce more efficient designs and owners determine when to replace or maintain equipment. Specific types of simulation, such as hardware-in-the-loop (HIL) testing, simulate real-world conditions by replacing a physical system with a virtual representation of that system.

Other technologies, such as virtual reality (VR), augmented reality (AR) and extended reality (XR), are also finding new applications in aerospace. These technologies enable immersive experiences that help teams walk through 3D designs interactively, improving communication and aiding decision-making processes.

Automation can be used to improve efficiency in both design and manufacturing processes. By reducing repetitive steps, engineers, technicians and other professionals can increase productivity and improve quality.

Artificial intelligence, which is impacting all aspects of daily life, is advancing in aerospace as well. Engineers are using AI to make predictions, recommendations, and decisions much as humans would, given similar objectives and a relevant knowledge base. AI tools offer conversational interfaces that can streamline analytical processes, enabling engineers to focus on more critical thinking and creative designs.

Improved manufacturing processes

Advanced manufacturing processes such as 3D printing (additive manufacturing) can produce custom products with less energy and waste when compared with conventional manufacturing. Lean manufacturing can reduce waste by streamlining production and increasing efficiency. Other energy-efficient processes, such as variable-speed motors, computer numeric control (CNC) tools and other advanced machinery, can also reduce energy consumption.

Manufacturing facilities can also use renewable energy sources, similar to aircraft, to reduce emissions and energy consumption. Solar, wind and bio-based fuels can be used to power manufacturing plants, reducing the carbon footprint of the aerospace industry. Manufacturing plants can also reduce CO₂ emissions through technologies such as particulate filters and catalytic converters. Low-emission coatings and paints reduce the release of volatile organic compounds (VOCs) into the atmosphere.

More efficient use of natural resources can also improve sustainability. Water usage can be reduced with more water-efficient processes and equipment. Stormwater management practices can reduce pollution from surface runoff and manufacturing processes. Recycling of water can be introduced to reuse non-potable water. Recycling and reusing other materials, such as metals, wood, paper and plastic can reduce waste and resource consumption.

Optimized airport and flight operations

Optimized flight paths and air traffic management can improve efficiency, reducing fuel consumption and emissions. Airlines and airport operators can use advanced analytics and machine learning to improve efficiency. Aircraft adjustments such as engine modifications for improved aerodynamics can improve combustion and airflow, also reducing consumption and emissions.

Airport infrastructure can be designed and constructed with more sustainable materials and processes. As with manufacturing facilities, airports can use renewable energy sources, implement water management practices, and incorporate more green building materials to reduce CO₂  emissions. Public transportation for passengers and airport workers can reduce fuel consumption and emissions.

Lifecycle assessments

Lifecycle assessments (LCA) evaluate the environmental impact aircraft and their components across their entire lifecycles, identifying potential areas of sustainability improvement. This can include everything from raw material acquisition through design and manufacturing to operation and end-of-life disposal. 

The aerospace industry has numerous opportunities to improve sustainability. Engineers and other professionals can use a combination of new techniques and materials, as well as improvements to conventional processes, to help guide these efforts.

The post What sustainable engineering practices are used in aerospace? appeared first on Engineering.com.

Often cited as the emissary of The Future (along with robot butlers and meals in pill form), the notion that flying cars would become commonplace was largely dismissed by most seriously minded engineers until 2009. That was the year that a video of NASA’s Puffin concept – based on a technology dubbed ‘distributed electric propulsion’ – hit YouTube.

Since then, urban air mobility (UAM) enabled by electric vertical takeoff and landing (eVTOL) technology has gone from pie in the sky to actually in the sky, with development efforts from both legacy OEMs – including Airbus, Boeing, and Honda – as well as start-ups such as Archer Aviation, Joby Aviation, and Volocopter.

Most recently, Joby Aviation announced successful flights in Dubai and Archer Aviation announced that it had successfully completed an initial flight of its Midnight aircraft in Abu Dhabi. The locations of those test flights (both in the United Arab Emirates) is not a coincidence, and it points to the biggest hurdle facing eVTOLs today. But before we get into that, let’s take a look at what eVTOL technology is and what it’s potentially capable of.

eVTOL Technology

There are several categories of eVTOL designs. These include multirotor (essentially large drones, such as the Volocopter 2X and EHang 216), lift + cruise (with separate rotors for vertical lift and horizontal cruise, such as the Joby S4), tiltrotor and tiltwing (such as the Bell Nexus), and vectored thrust (with fixed wings and rotors, such as the Archer Maker).

Broadly speaking, eVTOL vehicles are designed to utilize vectored thrust, many with rotors or propellers oriented vertically for takeoff and landing and horizontally for cruising. This also means that, while some eVTOL aircraft incorporate tandem or box wings in their designs, most rely primarily on their rotors to generate lift. Similarly, while there are examples of eVTOL vehicles that use hydrogen fuel cells (such as the Skai from Alaka’i Technologies), most are battery powered.

Indeed, it’s the electric nature of their propulsion systems that makes eVTOL aircraft unique. After all, vertical takeoff and landing aircraft have existed since the 1960s, but compared to the complex jet engine designs of the Harrier Jump Jet and its ilk, eVTOL is significantly simpler. In theory, this should enable eVTOLs to be less expensive to manufacture and operate, as well as promoting redundancy and thereby improving their tolerance for failure and enhancing their safety.

eVTOL applications

Perhaps the most obvious (or at least the most publicized) use case for eVTOL is on-demand passenger services, aka air taxis. At one time, Uber Elevate proposed to lead the charge on this initiative, but the company’s sale of that business segment to Joby Aviation suggests that it’s grown less optimistic about the prospects for eVTOL in UAM.

Then there are the possibilities for package delivery, with Google-owned Wing, Amazon Prime Air and even UPS all competing to become the leader in this potential market. It’s worth noting, however, that this application tends to blur the line between eVTOL conceived as aircraft capable of transporting people and (relatively) more conventional  autonomous drones.

Finally, and perhaps most excitingly, there is the potential to use eVTOL aircraft for public services, such as firefighting, search and rescue, and disaster relief. A 2021 NASA white paper on eVTOL technology for public services argues that these are the most promising use cases for the technology, since they tend to garner greater public support and are generally subject to fewer regulatory constraints than commercial civilian applications like air taxis or package delivery.

eVTOL challenges

The same NASA white paper that argues in favor of eVTOL for public services is also quick to point out their biggest technical challenge: energy density. According to the paper, packed Li-Ion batteries have a specific energy of 230-260 Wh/kg at the cell level and 180-200 Wh/kg at 3-6˚C discharge rate. That’s significantly lower than the hydrocarbon fuels used in conventional aircraft, which have a stored energy density of 12,000 Wh/kg.

Not only does this limit the effective range of eVOTL aircraft, it also doesn’t account for the additional weight necessary to meet the thermal management and safety requirements of electric aircraft that are approved for commercial aviation. Moreover, FAA certification requires a demonstration of recovery mechanisms in case of mechanical failure, and what that solution actually looks like in the case of eVTOL is still unclear.

That’s why – until the relatively low energy density of batteries can be addressed – eVTOL aircraft may be limited to use in countries outside the FAA’s jurisdiction.

The post An introduction to eVTOL aircraft appeared first on Engineering.com.