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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

• Jim Orbon, Head of Programs,

• 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,

• 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

• Kevin Cain, Chief Technical Officer,

• 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 

• Anastasia (Stacy) Biel, Segment Manager — UAM & DoD, Toray

• 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,

• 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.

3:15-3:20 PM

• Scott Francis, Editor-in-Chief, ÂÌñÏ×ÆÞ