The development of eVTOL (electric vertical takeoff and landing) aircraft has driven significant innovations, but the choice of configuration—such as vectored thrust or cruise lift—plays a crucial role in the performance, efficiency, and commercial viability of these aircraft. Analyzing these configurations, along with the challenges faced by companies in the sector, helps to understand why many of them are struggling to turn technological promises into viable products.
Vectored thrust eVTOLs, like the Shield AI V-BAT, use a single propulsion system for all phases of flight, tilting or rotating the thrust vector to transition between vertical takeoff, horizontal flight, and landing. This design drastically reduces aerodynamic drag by eliminating the penalty of carrying inactive rotors during cruise. Additionally, the use of a single combustion engine in the V-BAT simplifies propulsion compared to fully electric systems, which require multiple motors and complex battery management. This approach results in greater range, reliability, and lower maintenance load, making vectored thrust platforms more suited for long-range missions and high operational demand. However, this concept requires advanced engineering to ensure precise control during transitions between flight modes, which can increase initial development costs.
On the other hand, cruise lift eVTOLs, like Embraer’s EVE, use dedicated rotors for takeoff and landing, while fixed wings and a rear propeller provide horizontal propulsion. Although this approach simplifies the transition between flight regimes and allows separate optimization of each system, it introduces significant inefficiencies. The lift rotors, once deactivated, generate drag during cruise, reducing speed and range compared to vectored thrust configurations. Furthermore, managing multiple electric systems consumes more energy and imposes greater thermal stress on the batteries, further limiting operational efficiency. These disadvantages make this type of eVTOL less suitable for long-distance or high-payload missions.
Systemic Challenges in the eVTOL Sector
In addition to technical issues, the eVTOL industry faces structural obstacles that hinder the viability of these projects. The development and certification cost of a new model can exceed 1.5 billion dollars, a massive investment that few companies can sustain. At the same time, the stringent regulatory and safety requirements add complexity to the certification process.
Another factor that has harmed the sector is financial speculation, driven by the wave of investments through SPACs (Special Purpose Acquisition Companies), which led to inflated valuations and market instability. As a result, many startups have failed to meet their operational and financial promises, revealing that much of the initial enthusiasm was not backed by solid fundamentals.
The Case of the Orbis eVTOL: Anticipating the Reality of the Industry
Back in 2012, we developed the Orbis eVTOL at Santos Lab, betting on an innovative quadrotor concept within an aerodynamic ring with a high-lift asymmetric profile. This design allowed for an extremely efficient transition between vertical and horizontal flight, making the Orbis one of the most advanced projects of its time. Presented at LAAD 2013, the Orbis made a huge impact and placed Santos Lab as the second most mentioned company in the media, only behind Embraer.
However, even with the success of the demonstration, we concluded that the VTOL would not have enough efficiency to become a viable product. Today, observing the challenges faced by companies in the sector, it is clear that our decision in 2012 was the right one. Only Shield AI, with its V-BAT, has managed to achieve an acceptable level of performance. The vast majority of eVTOL projects remain limited by technical and structural challenges that make their commercial implementation unfeasible.
Conclusion
Vectored thrust platforms, such as the V-BAT, demonstrate a clear advantage over cruise lift configurations, thanks to their aerodynamic efficiency, lower drag, and greater range. While the cruise lift concept offers versatility, its high costs, low energy efficiency, and operational limitations restrict its viability in competitive markets.
Combining technical challenges with financial and regulatory barriers, it becomes evident why most eVTOL companies have yet to deliver practical and sustainable solutions, despite the billions invested and the promises of a revolution in air mobility.
