How Manufacturing Trends Could Impact The EVTOL Revolution

Forbes

7 days ago

Robert Lane is the CEO and Cofounder of Manaflex, a global innovator of circuitry solutions for EV, energy and other industry sectors.
Electric vertical takeoff and landing (eVTOL) aircraft—which are battery-powered flying vehicles that are large enough to carry passengers—are an innovative form of urban transportation that offers a traffic-free and environmentally friendly alternative to ground-based transit methods.
Given recent developments in the field of batteries, aerodynamics and lightweight components, the industry is anticipated to expand rapidly.
While there have been some road bumps, eVTOL makers have raised $2.3 billion in 2024, up from the $1.5 billion raised in 2023, but down from the $3.4 billion in 2022 and $4.3 billion in 2021, according to Alton data cited by Reuters. Likewise, Aviation Week's fleet statistics estimate that approximately 2,000 eVTOL aircraft are expected to be deployed worldwide by 2030, growing to almost 12,000 by 2040 and 33,000 by 2050.
As CEO of Manaflex, which supplies eVTOL leaders with key operating components, it has been fascinating to watch this evolution. Here are a few of the trends I've seen in this space in recent years, and how they will impact the adoption of eVTOLs.
Building For An eVTOL Ecosystem
The success of eVTOLs depends on modern electronic and power technologies that enable lightweight design, efficient use of energy and high-reliability operations. The manufacturers that achieve commercial viability will be those that emphasize battery management, reduce electrical weight and maximize power distribution.
Leaders in this space are also looking to facilitate flight modifications via enhanced aerodynamics and real-time diagnostics—augmented by smart sensors. In addition, manufacturers are also building systems that lean on aluminum-based circuitry over copper systems, which can result in lower-mass technology.
The industry as a whole is moving closer to widespread acceptance as new manufacturing processes enable automated, scalable production. In particular, compared to conventional copper systems, circuit mass can be reduced by approximately a third when using aluminum-based circuitry.
I've also seen a shift away from traditional wire-and-metal assembly and toward fully integrated systems, such as the direct embedding of circuits into structural composites. This includes advanced 3D printed circuit boards that blend stiff and flexible regions, which unlock even more weight and cost reductions.
This method could revolutionize both robotics and aircraft, as combined procedures that concurrently manufacture electronics and structure are replacing the traditional method of assembling disparate metal frames, as well as wiring harnesses.
What's Next For The eVTOL Industry
With 2.5 billion people projected to live in cities by 2050, traditional road transportation will become more crowded. In major U.S. cities, eVTOLs can reduce origin-to-destination time for travel by around 30% to 40%, rendering them a sustainable and scalable option.
However, the road—or rather, airpath—ahead doesn't come without challenges, despite rapid growth. Current energy densities—which restrict flight duration, payload capacity and battery efficiency—remain a major constraint. Likewise, to safely and effectively handle thousands of low-altitude aircraft, air traffic control and regulatory frameworks must evolve.
Additionally, infrastructure will require a large investment, especially in congested urban areas. Here are a few areas that will need to be improved:
• Vertiports: These are vital for eVTOL landing and takeoff, particularly in cities. For access and transportation integration, they must be placed strategically and based on demand. Rooftop or repurposed site solutions may be required due to space limits in urban areas.
• Infrastructure For Charging: Charging stations will need to be upgraded to support fast charging. This may require upgrades to the grid to manage large electricity loads. It will also be essential to develop standardized connectors and hardware. Utilizing renewable energy sources and intelligent energy management systems can improve grid efficiency and resilience.
• Air Traffic Management: For eVTOLs to safely integrate with conventional aircraft and drones, existing air traffic management systems must be modified. To handle large numbers of eVTOL travel, automated technologies may be required, as well as cutting-edge software to improve coordination and manage airspace complexity.
Certification and public acceptance are also essential. Communities need to be reassured about the accessibility, noise levels and safety of eVTOLs. Gaining confidence and incorporating eVTOLs into current transportation ecosystems will necessitate cooperation with governmental organizations and industrywide standards.
To gain this confidence, the industry must make transparency, safety and public involvement top priorities to increase public trust in eVTOLs. The public will be reassured that these aircraft meet high standards if they undergo stringent safety testing, demonstrate clear regulatory compliance and maintain strong collaborations with aviation authorities (such as the FAA and EASA).
Community engagement initiatives such as town halls, virtual tours and ride-along opportunities can help demystify the technology, and real-world pilot programs in controlled environments can demonstrate dependability and noise performance. Faster urban travel, less traffic, less pollution (in comparison to vehicles or helicopters) and enhanced emergency response capabilities are some concrete advantages that the sector should emphasize.
Lastly, eVTOLs must be framed as a safe and useful advancement in urban mobility rather than as a futuristic novelty, with the support of prominent aviation professionals and consistent messaging from reliable organizations.
The industry may radically revolutionize urban transportation as we now know it—reducing traffic, enhancing sustainability and developing new channels for communication and commerce—if these issues are addressed with concerted international effort.
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