The race to bring electric Vertical Takeoff and Landing (eVTOL) aircraft to market is accelerating rapidly. Engineers are continuously pushing the boundaries to maximize efficiency, extend flight range, and meet rigorous safety and sustainability standards. Traditionally, metals have been the trusted choice and backbone of aerospace designs, providing reliability, structural integrity, and proven performance. However, the unique requirements of eVTOL aircraft mean we must also look beyond conventional solutions to achieve groundbreaking innovations.
Weight management in eVTOL aircraft isn't just important—it's mission-critical. Every additional kilogram reduces flight range, increases energy consumption, and adds strain to battery systems. Unlike traditional fixed-wing aircraft, eVTOLs depend heavily on electric propulsion systems that require continuous lift rather than benefiting from forward motion and aerodynamic lift alone. This unique operational mode means that lightweighting becomes the defining constraint in the entire design process. Metals, while reliable and extensively proven, inherently limit design freedom due to constraints related to geometry, manufacturing complexities, and their relative density. As battery technology steadily improves but still faces limitations in energy density compared to traditional aviation fuels, every structural component in an eVTOL must be scrutinized for efficiency and weight optimization.
Next-generation thermoplastics and composite materials are complementing traditional metal solutions, offering engineers expanded possibilities for significant weight reduction without compromising performance. In specific eVTOL applications, these advanced materials can be up to 50% lighter than aluminium while matching or even exceeding mechanical strength and durability. Beyond mere weight reduction, these materials provide engineers with greater design flexibility. Complex geometries, integrated functional parts, and simplified manufacturing processes become feasible, allowing for innovations previously limited by traditional materials. This expanded design freedom is a crucial enabler for achieving next-level performance in eVTOL designs.
Structural elements such as landing gear, motor mounts, and chassis reinforcements particularly benefit from composite materials, which effectively absorb impact and vibration while significantly reducing overall mass. In battery housings, advanced thermoplastics offer improved thermal management, structural integrity, and flame-retardant properties—critical aspects for safety and performance. Electrical powertrain components, such as e-motors, inverters, and busbars, benefit from flame-retardant polymers that enhance safety, performance, and longevity. Additionally, advanced lightweight materials improve responsiveness and durability in aerodynamics and control systems, such as actuators, bearings, and gearboxes.
Transitioning toward advanced materials doesn't mean completely abandoning metals; rather, it's about strategically incorporating a broader range of solutions that align with the stringent requirements of eVTOL designs. This approach requires a thoughtful shift in engineering practices—rethinking structures, optimizing manufacturing, and meeting stringent compliance standards. At Envalior, we collaborate closely with engineers to integrate advanced materials into innovative solutions tailored explicitly for eVTOL applications. Leveraging cutting-edge simulations, sustainability initiatives, and comprehensive engineering support, we help manufacturers overcome the unique challenges of this rapidly evolving industry.
The future of air mobility is built on innovation and a willingness to explore new possibilities. Are you ready to engineer the next generation of flight?
System Expert
Ron Krotwaar is system expert in lightweighting and holds a Master of Science Degree in Mechanical Engineering obtained at the Technical University of Eindhoven. Since 1999 Ron has held many roles at Envalior, most recently focusing on lightweighting, automotive powertrain, structural parts and robotic arms.
Bart Reijmers is an Advanced Development Expert with a focus on conceptual design and engineering. In this role, he provides design support to customers in various industry segments and a wide range of applications. Bart always strives to find the ideal combination of material, design, and manufacturing technology. This way, the specific properties of Envalior's materials are optimally utilized and their value for customers is maximized.
17 March 2025
3 min read
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