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Forbes
06-08-2025
- Automotive
- Forbes
How Manufacturing Trends Could Impact The EVTOL Revolution
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. Forbes Technology Council is an invitation-only community for world-class CIOs, CTOs and technology executives. Do I qualify?
Fast Company
24-07-2025
- Business
- Fast Company
Manufacturing plants: Four factors to consider when choosing a stateside location
Traditionally, factory expansion decisions have been based on basic indicators such as labor costs, land values, and accessibility to suppliers. While these factors are still significant, they no longer provide the entire picture. Today, location has grown beyond a mere logistical factor to a potent strategic lever capable of driving long-term growth—particularly as manufacturing adopts sophisticated technology and sustainability objectives. According to research conducted by the Council of Supply Chain Management Professionals and McKinsey & Company, factors such as cost of transportation, workforce availability, and marketplace proximity can influence profitability by up to 50%, making cautious site selection one of the most important decisions manufacturers face. We at Manaflex, a business that specializes in localizing modular manufacturing lines for advanced circuitry manufacturing solutions, and our team recently underwent a rigorous site selection procedure for our first plant in the United States—Vancouver, Washington. If you're looking to make a location change, here are some of the things we considered in our selection process that you might find useful. 1. A WORKFORCE BUILT FOR FUTURE INDUSTRIES Subscribe to the Daily newsletter. Fast Company's trending stories delivered to you every day Privacy Policy | Fast Company Newsletters Automation, artificial intelligence, and the electrification of all things, from infrastructure to automobiles, are drastically changing manufacturing. The manpower needs for contemporary factories are being redefined by this change. The U.S. Bureau of Labor Statistics projects that employment of industrial engineers, who play a key role in high-tech manufacturing, would increase by 12% between 2022 and 2032, which is much faster than the median rate for all occupations. Now, states that make investments in partnerships for technical education and upskilling are more desirable than those that only consider labor availability. In our instance, we gave preference to areas with established pipelines via universities, where automation and materials science programs are well aligned with the demands of the local business. 2. INFRASTRUCTURE AND ECOSYSTEM The density and variety of the local supplier base in certain advanced manufacturing groups is an underappreciated advantage. A strong in-state supplier ecosystem may save lead times, improve product quality, and protect against global disruptions for anything from circuits to specialized polymers, battery components, and particular tooling. Manufacturers operating at a global scale cannot afford supply chain bottlenecks. Proximity to multimodal transport systems—highways, ports, rail, and air freight—is now part of the competitive equation, especially for companies shipping high-value or time-sensitive components. In real terms, excellent infrastructure reduces market times and increases supply chain resilience, which is crucial in industries like solar materials and EV components where time-sensitive deliveries and worldwide rivalry are widespread. 3. SUSTAINABILITY Clean energy leadership is not only an environmental commitment; it is an economic strategy. Accessibility to low-carbon energy has grown into a commercial necessity as global sectors unite around net-zero objectives. Customers and investors increasingly demand that many manufacturers reduce emissions throughout their operations. Location is crucial in this situation. In an economy that is becoming more and more concerned with carbon emissions, the difference it can make translates into reduced operational costs and a higher environmental profile. 4. PUBLIC-PRIVATE SYNERGY Ecosystem support is another important yet frequently disregarded component. The most prosperous areas are those where businesses, educational institutions, and local governments collaborate. This can be in the form of shared infrastructure, training funds, accelerated permitting, or access to R&D facilities. advertisement These kinds of initiatives show that a region is committed to fostering forward-thinking manufacturing while also assisting businesses in scaling clean technology. LOCATION STRATEGY IS BUSINESS STRATEGY Often enough, a location is viewed as a tactical choice that operations teams should maximize. However, as we discovered while expanding, location needs to be viewed as a multifaceted part of an overall corporate strategy. A well-selected location can help you access the next wave of technical talent, accelerate your time to market, and lower your energy footprint. In order to create long-term value, it can also integrate your business into an innovative ecosystem where private and public objectives coincide. Business executives should consider the following when deciding where to grow or relocate: • Do the government and local institutions support industry and innovation? • Are there additional benefits, such as a free Trade Zone or tax benefits? • Is there inexpensive, dependable, and clean energy available in this area? • Does advanced manufacturing have a skilled or adaptable workforce? • What is the climate of the local and state governments for this industry? • To what extent is the transportation network robust and interconnected? In our experience, if such responses offer affirmative advantages, then expansion of manufacturing in the USA turns into a strategic benefit rather than just a real estate choice. The capacity to connect to a robust, future-ready ecosystem may progressively define the success of businesses navigating their next stage of expansion, particularly those in the fields of advanced materials, electrified transportation, and renewable energy.
Fast Company
13-06-2025
- Business
- Fast Company
Energy storage systems: Advancing a sustainable future
Globally, renewable energy is achieving remarkable progress, yet there is a challenge to think about: What do we do when the sun doesn't shine, or the wind doesn't blow? Energy Storage Systems (ESS) come into play, serving as the primary component of a reliable and sustainable power grid. Energy storage technology is developing rapidly, from massive battery farms that improve grid stability in Texas to creative gravity storage solutions in China. The energy storage market is expected to grow at an impressive 14.8% annual rate, from its estimated $58.9 billion in 2024 to $204.8 billion by 2033. According to GlobeNewswire, the U.S. market is expected to grow at a compound annual growth rate (CAGR) of 13.9%, from USD 21.9 billion in 2024 to an impressive USD 70.7 billion by 2033. Organizations like mine, Manaflex, are leading this revolutionary shift by rethinking the architecture and design of circuitry solutions as it relates to energy storage systems. THE IMPORTANCE OF ENERGY STORAGE ESS ensure a consistent power supply by storing excess energy generated during peak periods and releasing it when demand is high or renewable generation declines. In order to reduce our reliance on fossil fuels, prevent blackouts, lower energy costs, and promote energy independence, this technology is vital. ESS is becoming an essential aspect of the energy landscape as more households, companies, and countries switch to renewable energy. The international market for thermal energy storage is anticipated to grow rapidly, possibly tripling in size by 2030, according to the International Renewable Energy Agency (IRENA). It is projected that installed capacity will increase from gigawatt-hours (GWh) in 2019 to more than 800 GWh by 2030, propelling the shift to a low-carbon economy and expanding access to clean energy globally. THE ESS REVOLUTION AND THE RACE FOR BETTER BATTERIES While energy storage technology has advanced significantly, the most intriguing developments are taking place at the component level. Conventional lithium-ion battery systems are still expensive and have limited material options, despite their widespread use. WHY ESS MATTERS NOW MORE THAN EVER Beyond just keeping the lights on, energy storage is critical to the widespread use of renewable energy sources. For instance, Texas saw a 5,500% increase in battery storage capacity in 2024, making grid stability more dependable and affordable than ever. In a similar vein, California is working toward 24/7 clean energy, which calls for large investments in storage technologies to guarantee that solar and wind power are reliable all year long. LOOKING AHEAD The energy storage industry will undergo significant change over the next five years. Global installations are predicted to increase by 76% to reach 69 GW/169 GWh by 2025. Energy storage will become more affordable, more effective, and more widely available as a result of innovation by companies. However, there are still significant obstacles facing the sector, such as high initial costs, restricted access in developing nations, and supply chain limitations for essential minerals. In order to reduce costs and enhance worldwide accessibility, companies and suppliers must emphasize design effectiveness, scalable manufacturing, and collaborative innovation. With recent advances in design, production, and materials, the competition for improved ESS is only beginning. Leading the path is more important than merely keeping up.
