The aviation industry stands at a transformative moment as we enter another year of innovation, with electric vertical takeoff and landing aircraft (eVTOLs) leading the sustainable revolution. As regulatory changes drive electrification and innovations in lightweight materials advance, these aircraft promise environmental sustainability, cost-effectiveness, and urban air mobility solutions. With our cutting-edge materials and expertise, our team at Carpenter Electrification is actively shaping this aviation future through advanced alloy solutions and optimized manufacturing processes.
2025 Industry Milestones
The electric aviation sector is poised for significant advancement in 2025, with several major milestones on the horizon. Leading manufacturers like Joby Aviation and Archer Aviation are finalizing certification processes for their commercial eVTOL aircraft, with expected launches in key urban markets by the end of 2025. These certifications represent a crucial step toward the mainstream adoption of electric aviation. Companies in the regional air mobility sector are making substantial progress on electric aircraft designed for routes under 250 miles. Beta Technologies' ALIA eCTOL aircraft is scheduled for commercial service implementation across multiple cities.
The supply chain is rapidly evolving to support this growth, with major aerospace manufacturers increasing their investment in electrification. Industry data suggests a 40% year-over-year increase in the adoption of electric propulsion systems throughout the aerospace supply chain. Safran recently obtained EASA certification for a 120kW electric motor to replace the gas engine for propeller airplanes and is working on larger motors. Specialized manufacturing facilities for electric aircraft components are expected to double by 2025. This acceleration is particularly evident in motor and battery production, where new facilities are explicitly optimized for aviation-grade electric components.
Our advanced alloys, strip processing expertise, and stack production capability
enable these transformations, providing the foundation for lighter, more efficient electric aircraft. Our Hiperco® alloy technology is already integrated into several pioneering aircraft designs, supporting their certification processes through superior motor performance and reliability. The material's unique properties have proven essential for achieving the power density requirements necessary for commercial viability, while our optimized manufacturing processes are helping scale production to meet growing industry demand.
What to Know About eVTOLs
Let’s circle back to discuss this type of aviation in more detail. eVTOL aircraft use electric propulsion to take off and land vertically (like a helicopter), eliminating the need for extensive runway infrastructure. This technology is advancing aviation by making it more efficient, convenient, and environmentally friendly.
The electric motors in these aircraft, particularly those built with high-induction soft magnetic alloys and stacks, have a high power-to-weight ratio, making eVTOL aircraft highly efficient during power-intensive phases like takeoff, hover, and landing. After takeoff, eVTOLs transition into an efficient cruise mode like an airplane. This combination of features makes them ideal for short-range transit in dense urban environments that airplanes cannot access and where helicopters have been too disruptive to gain wide popularity.
One of the most notable features of electric aircraft is their quiet operation. Traditional aircraft powered by combustion engines generate a lot of noise due to the explosion of fuel and air mixture in the cylinders and the high-speed exhaust gasses. Electric motors are virtually silent, with most of the noise generated by air disturbance from the propellers. This significantly reduces noise pollution, making electric aircraft ideal for urban environments where noise can be a significant issue. Furthermore, using multiple smaller motors and propellers in eVTOLs, a concept known as distributed propulsion, can further reduce noise levels compared to a single large motor and propeller system.
Electric aircraft also stand out for their reduced maintenance needs, energy efficiency, flexibility in design, and potential for regenerating energy in flight. With significantly fewer moving parts than combustion engines, electric motors experience low wear and tear, leading to low maintenance costs and high reliability. They are often used in direct drive configurations, eliminating the complexity and weight of a gearbox —their high-efficiency results in less energy waste and lower operating costs. The compact and flexible nature of the electric motors allows for innovative aircraft designs, enhancing functionality and efficiency. Lastly, the potential for regenerating energy in-flight could further increase the efficiency of electric aircraft by using the electric motor as a generator during cruise in some aircraft designs.
For manufacturers developing next-generation aircraft for 2025 and beyond, Carpenter Electrification's soft magnetic alloys and optimized stack processing are critical enablers (as noted earlier). Our Hiperco® alloys directly address key challenges in electric aviation, particularly in power density and efficiency. For detailed technical specifications, visit our comprehensive datasheets for electric aircraft applications.
Hiperco®, a high cobalt alloy used in stators and rotors, is ideal for aircraft propulsion systems. This alloy strikes the essential balance between power and weight for electric motors, providing 30% higher power density and increased motor efficiency by up to 3%. This means an identically sized motor can have 25% higher torque than other alloys, or the same torque and power output can be achieved with a 30% reduced footprint. This is a significant advancement in electric aviation, promising more efficient, quieter, and sustainable air travel.
Watch Video: The Motor Putting the Electrification Revolution in Motion
Things to Consider for Future Impact
As we look toward the future of air travel, several factors must be considered.
Infrastructure and Charging Solutions
The scaling of electric aviation requires robust charging infrastructure, with current projections indicating a need for over 1,000 vertiports globally by 2028. Key challenges include developing standardized charging protocols capable of delivering megawatt-level power and ensuring sufficient grid capacity at vertiports.
This includes the development of infrastructure such as vertiports for vertical takeoffs and landings, as well as charging stations for electric aircraft. The transition to electric aviation will require a significant overhaul of existing airport infrastructure. Still, the benefits of reduced noise pollution, lower operating costs, and environmental sustainability make it a worthwhile investment. New vertiport facilities will open within cities, promising quick and convenient access to downtown locations. Existing airports will likely feature dedicated eVTOL landing pads and charging stations in the future, transforming the air travel landscape. Moreover, the development of fast-charging technologies will be crucial to ensure the efficient operation of these electric aircraft.
Public Perception
Public acceptance of eVTOLs will be crucial for their success. Recent market research indicates that many urban commuters would consider using air taxis if safety and reliability standards match traditional aviation. Current challenges include addressing range anxiety and establishing trust in autonomous flight systems. Companies also plan to keep prices low — around the cost of a premium Uber Black car ride. Major airlines like United, American Airlines, and Delta have already invested in eVTOL start-ups to develop this, indicating a growing acceptance of this technology. As more people become aware of the advantages of eVTOLs, public perception will likely continue to improve. Education and awareness campaigns will play a key role in shaping public opinion and fostering acceptance of this new form of air travel.
Environmental Impact
One of the most significant benefits of eVTOLs is their environmental sustainability. As they are electric, they do not produce carbon emissions during flight, making them more environmentally friendly than conventional aircraft that rely on fossil fuels. Current estimates suggest that the widespread adoption of electric aircraft could reduce aviation-related carbon emissions by up to 40% by 2035. The shift to electric and hybrid electric aviation, from either a battery or hydrogen energy source, is paramount given the 2% of total greenhouse gas emissions that air travel currently contributes yearly. However, challenges remain in battery production sustainability and end-of-life recycling, areas where advanced materials and manufacturing processes are driving improvements.
Government Laws and Regulations
Government regulations will play a crucial role in developing and deploying eVTOLs. Regulatory bodies must establish safety and operational guidelines for these new aircraft types. This will involve a careful balance between fostering innovation and ensuring passenger safety. As eVTOL technology continues to evolve, so will the laws and regulations governing its use. This will be critical to successfully integrating eVTOLs into mainstream air travel. Collaboration between industry stakeholders, regulatory bodies, and governments will be vital in creating a regulatory environment supporting electric aviation's growth and development.
Read More: What The Shift of Electric Aircraft Means for Aerospace
What is the Future of Air Travel for eVTOL?
Looking to the future, electric aviation promises significant changes in air mobility. eVTOL urban air mobility will alter travel within cities, improving transit times and lowering congestion. Regional air mobility solutions will connect cities with 15-30 passenger aircraft covering distances up to 250 miles. Carpenter Electrification's high-induction Hiperco® and stator and rotor stacks improve electric propulsion unit (EPU) performance for eVTOL and electric and hybrid electric airplanes. Our materials directly address key power density and motor challenges through improved efficiency. Modeling of various eVTOL designs has shown that Hiperco®-powered motors can increase payload capacity by one passenger, a significant improvement in profitability for airline operators.
As we look even deeper into the future, we can expect to see a sky filled with quiet, efficient, and environmentally friendly electric aircraft — primarily due to the vast potential applications of eVTOLs. They could serve as air taxis in urban areas, providing a quick and convenient mode of transportation that bypasses ground traffic. Flights will be shorter, averaging around 28 minutes, with one to six passengers and the pilot. Vertiports — the landing pads for eVTOLs — are much smaller than airports and will be located in multiple spots within a city. The benefits of eVTOLS will be most significant in large metropolitan areas with high traffic and frequent gridlock. eVTOLs, due to their unique takeoff and ability to land in remote areas, could also play a significant role in emergency services, providing rapid response capabilities when time is of the essence.
The commercialization of electric aircraft will transform air travel, bringing people worldwide more flexible, convenient, and clean transportation. This includes eVTOL aircraft, hybrid and full-electric airplanes for regional air mobility, and e-copters. We might even see the advent of flying cars and hoverbikes in the not-so-distant future.
Electric aircraft will need high-output motors and generators with lightweight and compact form factors for large-scale electrification to become a reality. Carpenter Electrification's high-induction Hiperco® alloys give e-motor designers the materials they need to achieve high power density, high torque density, and reduced size and weight. Our advanced stator and rotor stack manufacturing capabilities enable thin Hiperco® laminations, which are ideal for high-speed motors and generators, ensuring low core loss, continuous power operation, and lower operating temperatures.
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Reach Out to Discuss Electric Aircraft
Carpenter Electrification is at the forefront of this revolution, providing industry-leading soft magnetic alloys and stacks to optimize the performance of motors used in electric aircraft. To explore how our advanced materials can support your 2025 electrification needs or discuss partnership opportunities, connect with our team of experts today.
You can also visit our technical resource center for detailed insights into electric aircraft materials and sustainable air travel solutions. And if you're ready to revolutionize flight, our team is here to help address your motor design needs for current and future electric airplanes and eVTOLs.