Explore the cutting-edge composites industry, as experts delve into the materials, tooling, and manufacturing hurdles of meeting the demands of the promising advanced air mobility (AAM) market. Join us at CW Tech Days to unlock the future of efficient composites fabrication operations.
The burgeoning advanced air mobility (AAM) market promises to introduce a new mode of transport for urban and intercity travelers — particularly those who wish to bypass the traffic congestion endemic to the world’s largest cities.
The electric vertical take-off and landing (eVTOL) aircraft serving this market, because they depend on battery-powered propulsion, also depend on high-strength, high-performance composite structures produced at volumes heretofore unseen in the aerospace composites industry.
This CW Tech Days will feature subject matter experts exploring the materials, tooling and manufacturing challenges of ramping up composites fabrication operations to efficiently meet the demands of a challenging and promising new marketplace.
An email with the recording will be sent to those who cannot attend the event.
Landscape image credits: (left to right): Eve Air Mobility, Joby Aviation, NASA
Composites in Advanced Air Mobility Schedule:
Thursday, December, 7, 2023
All times U.S. ET
11:00-11:15 AM
Scott Francis, Editor-in-Chief, CW
Welcome/Introduction
11:15-11:45 AM
Finding the Balance: Advanced Materials for Commercialization Considerations
Abstract: Producing eVTOL aircraft for commercialization demands numerous material considerations. Blades, wings, and fuselage all have specific requirements, and developing a singular material solution through development is optimal. Identifying the right material for these areas requires engagement with partners at the engineering, supply chain, and leadership levels. This presentation will review Overair’s developmental considerations in selecting composite materials for use throughout our eVTOL aircraft, Butterfly, the specific demands that our advanced propulsion system requires, and how identifying the right material not only provides the confidence to enter flight testing but to create a highly configurable platform for multiple commercialization use cases.
11:45-12:15 PM
Developing composite solutions to meet the eVTOL market needs of today and tomorrow
Sam Hill, AAM Marketing and Business Development, Solvay; Edoardo Depase, Aerospace and Defense head of Marketing, Solvay
Abstract: Composite materials are being successfully adopted for certification and Low-Rate Initial Production (LRIP) eVTOL aircraft variants today. As demand for eVTOL grows, vehicle build rates will increase and the challenge of high-rate composite production will become a reality. Additional in-flight data will provide a greater understanding of specific component in-service performance which will validate future eVTOL component requirements.Today’s composite technology selection will be presented and contrasted against future market needs. Key market challenges will be identified and areas that will benefit from industry collaboration discussed. The challenge of scaling composite manufacturing in eVTOL will be brought into context of the broader aerospace and defense market needs.
12:15-1:00 PM: Break
1:00-1:30 PM
Composite Manufacturing Challenges for Start-Ups in the AAM Space
Abstract: Revolutions in battery technology and electric propulsion systems are enabling an exciting new era in aviation. This new generation of aircraft will rely heavily on composite manufacturing to offset the additional weight of the electric powertrain in order to achieve commercially viable operational ranges. A fully composite aircraft is a major undertaking even for established aircraft manufacturers and presents a severe hurdle to new entrants to the AAM space. This discussion will explore the key factors and concerns that make implementing composite materials particularly difficult for start-ups and the different paths available to navigate these challenges.
1:30-2:00 PM
Composite Materials for Advanced Air Mobility and Uncrewed Aerial Vehicles
Dr. Robert Yancey, Business Development Director, Hexcel
Abstract: The Advanced Air Mobility (AAM) market is emerging quickly as the next generation of efficiently transporting people and cargo in urban environments and underserved regions. The Unmanned Aerial Vehicle (UAV) market is growing rapidly for both defense and commercial applications. Both markets require advanced composite materials for lightweight and efficient operations. This webinar will cover the structural material challenges, opportunities, and solutions for the UAV and AAM industries. It will include discussion on the material selection criteria including cost, rate, quality, manufacturing process, automation, and certification.
2:00-2:15 PM: Break
2:15-2:45 PM
Composite Material Supply Chain Challenges and Considerations for AAM
As with any large-volume emerging aerospace market that relies heavily on composites, the advanced composites industry needs to examine how to optimize traditional practices in commercial aerospace and strategically plan for the anticipated growth and high-volume production of the AAM market. Consideration must also be given to electric-powered aircraft's unique material performance requirements. This presentation will examine the current and projected state of the AAM market and discuss the composite material supply chain challenges of a fast-paced, potentially high-volume emerging market through the lens of a traditional large-volume market such as aerospace and defense. We will also review material solutions that aid in the transition from low-rate initial production (LRIP) to high-rate initial production (HRIP).
2:45-3:15 PM
Achieving Scalability and Quality with Minimum Weight
Joe Brennan, Composites Manufacturing and Assembly Lead, Joby Aviation
Abstract: The manufacture of eVTOLs for the AAM market represents a paradigm shift in composite aerostructures fabrication. The combination of scale, quality and weight savings that this market demands requires the application of materials, manufacturing processes, process control and industrial automation at unprecedented levels. The entire composites industry supply chain will be tasked with meeting the needs of this important new end market. This presentation will review Joby’s composites manufacturing strategy for its first-generation eVTOL, its outlook for second-generation eVTOL manufacture, and the materials and process expertise the company needs — near- and long-term — to support its efforts in AAM.
Eddy currently serves as the Global Head of Marketing and New Business Development for Solvay Composite Materials. Prior to this role, Eddy had several commercial and technical roles such as Head New Business Development for Industrial Markets, Head of Sales for Aerospace & Defense and Applications Engineering Director. Prior to Solvay, Eddy worked at Boeing and Ferrari F1. He holds a Masters in ChemE and an MBA from the University of Washington
Sam Hill, AAM Marketing and Business Development Manager at Solvay. Sam has over 18 years of experience in the high-performance composite market, serving a diverse and global customer base in the Large Commercial Transport, Rotorcraft, Defence, Advanced Air Mobility and automotive sectors. Sam has held management roles in Solvay's Applications and Customer Engineering functions, supporting its customers with the adoption, qualification and industrialisation of composite materials. Sam has a Masters in Mechanical Engineering from the University of Liverpool.
Kevin Cain is the CTO of Aria Group, a company that specializes in innovative solutions for the transportation industry. He has a long history of working on cutting-edge projects that challenge the boundaries of engineering and design.
Kevin joined Clive Hawkins in founding Aria Group in 1997 and was able to share his expertise with many of the world’s leading transportation companies in providing them with groundbreaking solutions to the creation of their design prototypes. This involved combining the very latest in manufacturing technologies with sophisticated custom software solutions to oversee and accelerate these projects.
While the specifics of Kevin’s work remain undisclosed due to the confidential nature of the programs that Aria undertakes, the impact of his efforts can be seen across many fields from advanced air mobility, autonomous vehicles, next-gen composite manufacturing methods, and even motion pictures.
Kevin currently resides in Traverse City, MI with his wife Krista and three children.
Dr. Robert Yancey has filled numerous roles in his career including research, technology development, sales, management, business development, and executive roles. He currently leads business development for Hexcel which includes advanced materials, manufacturing, and engineered products. He has a technical background in composite materials, composite mechanics and micromechanics, design optimization, additive manufacturing, finite element modeling, and nondestructive evaluation. He holds a B.S. degree in Aeronautics and Astronautics from MIT, an M.S. degree in Engineering Mechanics from Virginia Tech, and a Ph.D. in Materials Engineering from the University of Dayton. He is Technical Excellence Committee Chair for SAMPE and an AIAA Associate Technical Fellow.
Joe Brennan is the Composites Manufacturing and Assembly Lead for Joby Aviation where he’s currently responsible for composite part fabrication utilizing hand layup as well as automated fiber placement processes, airframe structural assembly, paint, additive manufacturing (3D printing), tooling, and composites R&D. Prior to Joby, Joe started and managed Virgin Galactic’s manufacturing operation producing commercial spacecraft, delivered high volume UAV structures for Quatro Composites, and developed and helped launch production of Boeing's 787 composite fuselage.
Jim Orbon is the Head of Programs at Overair, overseeing the development of the company's eVTOL aircraft and the associated engineering teams. With a background rooted in aerospace development, including a decade-long tenure at Sikorsky Aircraft, Jim has held influential roles in engineering and leadership. He was a member of the core engineering teams on several high-speed prototypes within Sikorsky Innovations and previously on the CH-53K heavy lift platform.
Stacy, segment manager for AAM & DoD programs for Toray, has nearly 40 years of composite material experience in the large commercial transport, launch, satellite, and AAM markets. She has worked in engineering, specializing in testing and manufacturing, as well as composite material sales. Her strong sales background includes sale of composite materials – ranging from thermoset and thermoplastic prepreg to honeycomb and carbon fiber – catering to aerospace customers in the United States and Canada. Stacy holds a degree in Materials Engineer from Virginia Polytechnic Institute and State University (Virginia Tech).
Read More About Composites in Advanced Air Mobility
Tooling load-in is already underway ahead of the planned start of initial production beginning early 2025, while Stellantis and Archer work to finalize the exclusive contract agreement.
The companies’ first product from this partnership, aided by an additional $430 million raised by Archer, is planned to be a hybrid-propulsion VTOL that will target a potential program of record from the U.S. DOD.
A look at recently reported design, material and process innovations for composites-intensive battery enclosures, developed to support the ramp-up of EV and AAM vehicles.
VX4 eVTOL aircraft prototype begins untethered, piloted, thrust-borne testing following expansion of permit to fly from the UK Civil Aviation Authority.
Flight of first production aircraft fresh off Beta’s full-scale manufacturing line in Vermont is followed by Special Airworthiness certification from the FAA.
Despite court-approved insolvency filings and beginning first investor briefings, Lilium remains fully focused on re-emerging following restructuring, setting its sights on fresh investment to support the Lilium Jet.
Japan Airlines’ and Sumitomo’s joint venture company intends to purchase up to 100 Midnight aircraft to certify and commercialize AAM services across Japan.
VoltAero inaugurates its industrial facility in Rochefort for the final assembly line for the family of Cassio electric-hybrid aircraft, to incorporate composite elements.
The focus of accelerated development is on Manta’s Ann Plus vehicle model, offering a complete carbon fiber structure and VTOL and STOL operation capabilities.
Series C capital raise will be used to propel the certification of Beta’s composites-intensive Alia CTOL, Alia VTOL and electric motors, while directly supporting ramp-up of production, delivery of aircraft and chargers.
Two of its principal subsidiaries will file for insolvency and apply for self-administration, follows failed loan efforts from German parliament’s Budget Committee, Bavarian government.
