eVTOL viability will require significant innovations, report claims

The future of eVTOL aircraft will be enabled by rapid advancements in next-generation electric motors, batteries and computing technology as the idea of fully electric and sustainable aviation moves closer from science fiction to reality, according to the latest report by IdTechEx.

The report explores the potential for air taxis to improve journey times between poorly-connected locations in a way that is affordable, low emitting and quiet enough to operate within cities.

Read more: Liverpool aiming to be a driving force in drone tech

Many key players within the sector are moving for light certification with the intention to mass produce aircraft at more than 10-times the volume of today's aircraft manufacturers.

Analysts report work is currently underway to deliver the advanced technologies required to deliver on fully sustainable electric aircraft as well as the steps needed to build the supply chains and the report indicates a collaborative effort between eVTOL OEMs and their suppliers over the next decade will lay the foundation for future growth.

Over $4 billion has already been invested into the eVTOL market and recent announcements from industry leaders are set to raise a further $3 billion in capital.

Large aerospace players such as Honeywell and Rolls-Royce have already established specialist units for urban air mobility to explore technologies including electric and hybrid systems as well as other opportunities such as actuation and autonomous flight systems.

The report suggests the most critical technology to the success of eVTOL aircraft is batteries and significant advances must be made to increase energy densities to somewhere in the region of 400 Wh/kg owing to the inefficiencies of modern automotive batteries.

IdTechEx expects high demand on energy density, power, cycle life and safety will create opportunities and market entry points for emerging battery designs, including lithium metal solid-state batteries, which would be too expensive to produce for automotive but could find a market in the aviation sector.

Another burgeoning technology will be that of opportunity charging, the report states. It is likely eVTOL aircraft will have to charge their batteries between each flight, but high utilisation of the aircraft necessitates quick turnaround times at vertiports, which will limit available charge time.

Air taxi infrastructure will therefore need to incorporate ultra-fast charging, with the best-designed systems offering a considerable operational advantage.

The report says: "Our analysis of air taxi/passenger drone operations within Urban Air Mobility (UAM) suggests that there are frequently talked about areas for air taxi deployment which simply do not look viable, offering commuters no perceivable benefit at a greater expense.

"While viable aviation battery technology is still in its infancy, eVTOL manufacturers may explore other options for fuel such as hybrid-electric or cell-hybrid powertrains, integrating either current aircraft turbine and piston engines or fuel cells systems as generators to charge the battery in flight."

Read more: China's EHang to build vertiport in Italy, expanding into EU

The use of fuel cells, which generate electricity using hydrogen, could potentially extend the capability of air taxis whilst maintaining low emissions, though this does leave issues to be addressed around the production of green hydrogen.

Another crucial element of eVTOL design, the report states, is in the electric motors employed. Many eVTOL aircraft are designed around having six or more motors installed around the mainframe.

This could prove a challenge since a lightweight design is essential to prevent effects on aircraft performance while still enabling the air taxi to meet the power requirements for taking off and landing.

A lightweight design will also be critical to maximising eVTOL aircraft range and payload.

eVTOL architectures will require a variety of different carbon fibre composite materials to be designed and fabricated to optimally meet the aircraft performance requirements.

The report states there is still a multitude of opportunities for eVTOL aircraft for advanced material manufacturers including the production of primary and secondary structures, rotor blades and interiors.

Outside of the aircraft, there is still the issue of infrastructure. This ranges from the planning and construction of eVTOL ports which must effectively link different hubs to advanced systems for flight booking and security check-ins.

Read more: Coventry to host world's first eVTOL airport

The report's authors conclude: "For managing a high volume of aircraft in low-level airspace new software and systems for UAM traffic management will need to be developed and operated. This new industry will need to exploit robotics in smart factories for high volume production and provide the necessary maintenance, servicing, and spare parts to keep eVTOL aircraft operational.

Whilst there are many challenges to overcome, there is growing recognition that eVTOL aircraft may become extremely lucrative for companies willing to put in the early groundwork."

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