It is estimated that up to 25,000 eVTOL (electric vertical take-off and landing) aircraft could be in service worldwide by 2035. This figure represents more than 60% of today’s global civil helicopter fleet. These aircraft are set to play a key role in transforming urban air mobility, reducing congestion in cities, and providing a sustainable solution for short-range transportation. Once OEMs (Original Equipment Manufacturers) achieve certification, and the industry starts to increase production volumes, there will still be a number of constraints to address, from air traffic control and pilot availability to the deployment of vertiport networks. Below, we will explore these key challenges and the opportunities that could drive the growth of the eVTOL industry in the coming years.

Certification hurdles and safety requirements

The certification of eVTOL aircraft remains one of the biggest challenges for manufacturers. Unlike conventional fixed-wing aircraft, eVTOLs introduce new and complex technologies such as distributed electric propulsion, sophisticated autonomous systems, and cutting-edge safety features. Regulatory authorities such as the Federal Aviation Administration (FAA) and the European Union Aviation Safety Agency (EASA) are working on adapting existing regulations to ensure that these new vehicles meet stringent safety requirements.

The certification process is rigorous because it must ensure that eVTOL aircraft meet the highest safety standards before they can carry passengers. To achieve certification, manufacturers must demonstrate reliability under various operational conditions, similar to how early helicopters and commercial jets had to prove their airworthiness.

As such, manufacturers have invested heavily in redundancy and safety-critical systems to improve resilience against possible failures. Even so, achieving type certification is an intensive process that could take years, slowing the timeline for mass production.

Infrastructure development and vertiports

Another significant constraint in the expansion of the eVTOL market is the lack of infrastructure, specifically vertiports. Vertiports are essential for the efficient operation of eVTOL services. These facilities are more than just landing pads; they need to provide charging capabilities, maintenance facilities, passenger handling, and secure take-off and landing routes. Current airports, heliports, and urban rooftops can potentially be adapted to serve as vertiports, but substantial investments in infrastructure are required.

Successful implementation of vertiports also requires collaboration between municipalities, private investors, and local governments to ensure that they are located where they provide the most benefit. The development of this infrastructure is already underway in some major cities such as Los Angeles and Singapore, which are actively planning urban air mobility networks with vertiport deployment.

Air traffic management and regulatory challenges

The current air traffic management (ATM) system was designed for conventional aircraft, not for thousands of small, electric-powered aircraft operating at low altitudes. The increased density of eVTOL traffic, especially in and around urban environments, will pose significant challenges for existing air traffic controllers.

To handle the complexity of this increased air traffic, new technologies will need to be adopted, including Unmanned Aircraft System Traffic Management (UTM) systems. These systems, which are being developed by NASA and other agencies, will help integrate eVTOLs into the airspace safely. They rely on advanced algorithms, real-time data sharing, and machine learning to predict and manage flight paths, mitigate congestion, and avoid collisions.

Successful integration of eVTOLs into urban airspace will also require significant updates to current ATM regulations, which means ongoing coordination with regulatory agencies around the world.

Pilot availability and autonomous technology

Another major challenge for scaling up eVTOL operations is the availability of trained pilots. Unlike traditional aircraft, eVTOLs could require a different set of skills for piloting, particularly for those models that rely on semi-autonomous or autonomous technologies. Current commercial pilot training programs are insufficient to address this future need.

In the longer term, however, it is expected that many eVTOL aircraft will become fully autonomous, reducing or eliminating the need for a pilot on board. Several manufacturers, such as Joby Aviation and Volocopter, are already working on developing autonomous capabilities, which could further accelerate adoption once safety is proven. In the meantime, the availability of qualified pilots will remain a bottleneck that could limit the initial growth of the industry.

Scaling up production and supply chain challenges

Scaling up production to meet growing demand represents another critical hurdle for eVTOL manufacturers. Many of the components used in eVTOL aircraft are cutting-edge technologies that are not yet produced at scale. For example, battery technology is one of the most critical aspects of eVTOL performance. These aircraft require high energy density batteries capable of supporting frequent take-offs and landings with short recharging times. Lithium-ion batteries and the emerging solid-state batteries are still evolving, and their availability at an industrial scale will be essential for the growth of the eVTOL sector.

Another major challenge lies in the supply chain for composite materials. eVTOLs need to be lightweight, and their structures often rely on advanced composites to minimize weight while maximizing strength. These materials can be expensive and challenging to produce at the scale required for mass production. Manufacturers are thus seeking innovative ways to streamline production and secure reliable sources of materials.

Economic viability and market acceptance

Despite strong demand from potential customers, the eVTOL market could remain constrained until 2030 due to the high costs associated with developing, certifying, and producing these aircraft. The price point of eVTOL services needs to be competitive with existing modes of urban transportation to ensure widespread adoption. Economies of scale will play a key role in reducing costs over time, but until then, initial eVTOL services may be considered a luxury, targeting high-income individuals or specialized use cases such as medical transport.

Public acceptance is also a crucial component of eVTOL expansion. Issues such as noise, perceived safety, and environmental concerns will need to be addressed to gain widespread support. The technology for electric propulsion promises quieter operations than traditional helicopters, but noise will still be an issue in densely populated urban areas. Companies like Lilium and Joby are investing in noise reduction technologies to improve public perception and facilitate market acceptance.

Conclusion

While there is immense potential for the eVTOL industry, significant challenges must be overcome before these aircraft can become a mainstream mode of transport. Certification hurdles, infrastructure development, air traffic management, pilot availability, and production scaling are all critical factors that will determine how quickly the industry can expand once demand begins to grow. Despite these challenges, the promise of urban air mobility continues to drive innovation, with key players investing in technologies and partnerships that could lead to a revolution in how we think about urban transportation by 2035.

Note: As the industry continues to evolve, it will be important to keep an eye on regulatory developments and advancements in infrastructure. Stakeholders across the value chain—from policymakers to technology providers and urban planners—will need to collaborate closely to enable the future of urban air mobility.