Prineville, OR – (November 4, 2024): After announcing the first flight of the Switchblade flying car in November 2023, Samson Sky moved right into the next phase – production engineering. The company has announced that their efforts have yielded tremendous results, and they are now sharing their enhanced body design for what will be their production vehicles. “The new design improves performance and shortens the pathway to production by transferring much of what worked well in the test vehicle that flew into the new streamlined design,” stated Sam Bousfield, Samson Sky CEO and designer of the Switchblade, citing that the new design is simpler and much easier to build.

“Everything we do is with the mindset of how we are going to produce thousands of Switchblades to meet the incredible demand we have,” added Bousfield.

Samson officials have stated that the company’s existing reservations represent a potential sales value of over $450 million. They have reservation holders from 57 countries, including all 50 U.S. states.

The Switchblade is a three-wheeled, street-legal flying car, often referred to as a roadable aircraft. Unlike traditional aircraft, roadable aircraft are designed to function both on the ground as cars and in the air as planes. With a focus on versatility, the Switchblade aims to address the growing interest in urban air mobility by providing a solution that can navigate through both crowded roads and open skies.

Improving performance and meeting customer demand

The company reported that they validated many key parameters during flight testing, and the new design elevates the Switchblade to the next level. “Many people don’t know that a company developing a brand-new aircraft never goes into production with their initial design,” stated Bousfield. “There are always changes and modifications based on things learned from flight testing, and we’ve used these to improve even more on our original design, while keeping our signature swinging wings that tuck away completely inside the vehicle when driving.” The final design shows refinements for production, including folding side wing mirrors, a nose radiator inlet, performance radiator outlet, headlights, and taillights.

The swing-wing technology employed in the Switchblade is a crucial feature that sets it apart from other roadable aircraft. Swing wings are designed to retract entirely into the body of the vehicle when it is in driving mode, significantly improving road safety and aerodynamics. During flight mode, the wings extend, providing the necessary lift for flying. This dual capability was refined through flight testing to ensure the highest level of functionality and safety for both road and air environments.

Engineering and wind tunnel testing

The company’s website describes the Switchblade as a high-performance vehicle, both on the road and in the air. The test vehicle that flew in 2023 achieved its target of 125 mph in ground testing, and company officials have stated that they made these design changes to achieve their flying cruise speed target. According to Bousfield, wind tunnel testing in May validated that the new design with the sleeker body and thruster propellers will allow Samson to meet their target of a 160-mph flying cruise speed.

Wind tunnel testing is a standard practice in the aviation industry, used extensively by companies such as Boeing, Airbus, and Cessna. The process involves placing a scaled-down or full-size version of the aircraft in a controlled environment where airflow is simulated to measure lift, drag, and other aerodynamic forces.

Wind tunnel testing provides critical data that can predict an aircraft’s performance under real-world conditions, with a typical accuracy of within 3% of actual performance. “Since that time, the final styling that we accomplished, which is shown here, ended up reducing drag by an additional 2%,” said Bousfield. This reduction in drag is a significant achievement, as it directly contributes to improved fuel efficiency, speed, and overall performance. Bousfield explained that this gives Samson the green light for production with the enhanced body design.

Bridging the gap between concept and production

One of the significant challenges faced by flying car manufacturers is the transition from concept to mass production. In the case of the Switchblade, the focus has been on improving production efficiency while maintaining quality and performance.

Samson Sky is building three production vehicles over the next 18 months to be used for intensive testing on every aspect of the vehicle, both flying and driving, prior to ramping up production. This step is vital for certifying the vehicle’s safety and functionality in both road and air modes. The company has adopted an approach similar to that used by Tesla in refining their vehicles through iterative design improvements based on real-world testing and data.

The Switchblade is being marketed as a flying sports car, combining the capabilities of both an aircraft and a high-performance road vehicle. Unlike many other experimental aircraft, the Switchblade is designed to be driven to and from an airport, where it can quickly transform into flight mode. In driving mode, the wings are safely stored inside the body of the vehicle, enhancing safety and durability. This makes it different from most ultralight aircraft, which are generally not capable of functioning as road vehicles. The Switchblade seats two, side-by-side, with room for travel bags, and flies up to 500 miles on a single tank of premium auto gas.

Meeting regulatory requirements

Another crucial aspect of the Switchblade project is regulatory approval. Samson Sky is pursuing certification from aviation authorities to ensure that the Switchblade complies with safety and operational standards for both road and air use. Federal Aviation Administration (FAA) certification, along with other international aviation standards, is a critical milestone. Achieving this certification requires rigorous testing, documentation, and adherence to strict safety guidelines, which often include demonstrating the vehicle’s resilience under various environmental conditions and its performance in emergency scenarios.

The road-legality of the Switchblade also adds an extra layer of complexity, as it must comply with both aviation and road vehicle standards. To overcome this, Samson Sky has worked closely with automotive engineers to ensure that the vehicle meets all safety and emission standards required for public road use in multiple countries. This dual compliance is a major selling point for the Switchblade, as it aims to be the first commercially available flying car that can operate seamlessly in both air and road environments without requiring a trailer or additional support.

Practical use cases and customer interest

Interest in flying cars like the Switchblade is driven by the increasing desire for more flexible and efficient travel solutions, particularly in urban areas where congestion is a major issue. According to industry estimates, the global urban air mobility market is projected to reach $12.4 billion by 2030, largely due to advancements in technology, increased investment in infrastructure, and rising consumer interest.

The Switchblade’s unique capability to transition from road to air is expected to appeal to consumers who are looking for innovative ways to bypass congested highways and reduce overall travel time.

Samson Sky’s approach also reflects an understanding of practical needs. Unlike some other flying car projects, the Switchblade is not just for personal enjoyment or niche applications. It is designed to be a viable option for everyday travel. For instance, business professionals who need to travel frequently between cities that are not well-serviced by airlines may find the Switchblade particularly appealing. By combining the convenience of road travel with the speed of air travel, the Switchblade offers a versatile transportation solution that could transform how people think about commuting.

The existing reservations for over $450 million in potential sales underline the demand for such a vehicle. The interest spans across 57 countries, which illustrates the broad appeal and the growing global market for flying cars. Reservation holders come from diverse backgrounds, including business owners, aviation enthusiasts, and individuals looking for the next big advancement in personal mobility.

The future of flying cars

The development of the Switchblade represents an important step in the broader movement toward urban air mobility. Companies like Samson Sky are part of a wave of innovation that aims to reshape the way we think about transportation. With advancements in autonomous technology, battery efficiency, and materials science, the possibility of a flying car becoming a mainstream product is no longer the stuff of science fiction. The Switchblade’s production represents not only a milestone for Samson Sky but also an important signal that the future of personal flight is closer than many people think.

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